U.S. patent application number 11/410942 was filed with the patent office on 2006-10-26 for developer cartridge for image-forming device.
This patent application is currently assigned to Brother Kogyo Kabushiki Kaisha. Invention is credited to Isao Kishi, Tsutomu Suzuki, Takeyuki Takagi.
Application Number | 20060238599 11/410942 |
Document ID | / |
Family ID | 36754084 |
Filed Date | 2006-10-26 |
United States Patent
Application |
20060238599 |
Kind Code |
A1 |
Kishi; Isao ; et
al. |
October 26, 2006 |
Developer Cartridge for image-forming device
Abstract
A developer cartridge provided in an image-forming device has a
developer side casing that includes a toner-accommodating chamber
and a developing chamber; and a plate wall disposed in the
developing chamber for partitioning a thickness-regulating blade
from the toner-accommodating chamber. When a thickness-regulating
blade scrapes excess charged toner off the developing roller, the
plate wall prevents this charged toner from returning to the
toner-accommodating chamber. A flexible wiper for cleaning toner
detection windows is attached to an agitator for stirring toner in
the toner-accommodating chamber via a fixing member. The fixing
member includes a support plate and a gripping plate disposed
opposite each other with a slit formed therebetween. The wiper is
inserted into the slit and is fixed to the fixing member when a
boss protruding from a restricting plate becomes inserted into a
through-hole formed in the wiper.
Inventors: |
Kishi; Isao; (Nagoya-shi,
JP) ; Takagi; Takeyuki; (Nagoya-shi, JP) ;
Suzuki; Tsutomu; (Nagoya-shi, JP) |
Correspondence
Address: |
BANNER & WITCOFF, LTD.;ATTORNEYS FOR CLIENT NOS. 0166889, 006760
1001 G STREET, N.W., 11TH FLOOR
WASHINGTON
DC
20001-4597
US
|
Assignee: |
Brother Kogyo Kabushiki
Kaisha
Nagoya-shi
JP
|
Family ID: |
36754084 |
Appl. No.: |
11/410942 |
Filed: |
April 26, 2006 |
Current U.S.
Class: |
347/140 |
Current CPC
Class: |
G03G 2221/163 20130101;
G03G 15/0862 20130101; G03G 15/0877 20130101; G03G 15/0875
20130101; G03G 2215/0897 20130101; G03G 2215/0802 20130101 |
Class at
Publication: |
347/140 |
International
Class: |
G03G 13/04 20060101
G03G013/04 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 26, 2005 |
JP |
2005-128502 |
May 11, 2005 |
JP |
2005-138729 |
May 13, 2005 |
JP |
2005-140893 |
Jun 3, 2005 |
JP |
2005-164321 |
Claims
1. A developer cartridge comprising: a developer-accommodating
chamber that accommodates developer; a developer-carrying member
that carries developer; a supplying member that charges and
supplies developer accommodated in the developer-accommodating
chamber to the developer-carrying member; a thickness-regulating
member that contacts the developer-carrying member at a contact
part with pressure to regulate a thickness of developer carried on
the developer-carrying member; and a wall having a base end and a
distal end and disposed between the developer-accommodating chamber
and the thickness-regulating member, the distal end of the wall
being positioned closer to the supplying member than the base end
of the wall, the wall partitioning the thickness-regulating member
from the developer-accommodating chamber such that a distance
between the supplying member and the distal end of the wall is
shorter than a distance between the supplying member and the
contact part at which the thickness-regulating member contacts the
developer-carrying member.
2. The developer cartridge according to claim 1, further comprising
a casing formed of the developer-accommodating chamber, a
developing chamber, and a partitioning wall, wherein the developing
chamber accommodates the developer-carrying member, the supplying
member, and the thickness-regulating member, and the partitioning
wall partitions the developer-accommodating chamber from the
developing chamber and has a through-hole formed therein for
providing communication between the developer-accommodating chamber
and the developing chamber, and wherein the wall is formed in the
developing chamber.
3. The developer cartridge according to claim 2, wherein the base
end of the wall is connected to the casing and the distal end of
the wall is disposed between the contact part at which the
thickness-regulating member contacts the developer-carrying member
and a portion of the supplying member nearest to the
developer-accommodating chamber with respect to a direction in
which the developer-accommodating chamber adjoins the developing
chamber.
4. The developer cartridge according to claim 3, wherein the
developer-carrying member is disposed in confrontation with the
supplying member on the side of the supplying member opposite the
developer-accommodating chamber with respect to the direction in
which the developer-accommodating chamber adjoins the developing
chamber, and wherein the thickness-regulating member has a mounted
end supported on the same side of the casing as the base end of the
wall portion, and a free end disposed near the wall portion, the
contact part of the thickness-regulating member being disposed on
the free end thereof for contacting the developer-carrying member
with pressure, the thickness-regulating member gradually
approaching the wall from the mounted end to the free end.
5. The developer cartridge according to claim 4, wherein the
developer-carrying member rotates a direction so that developer
supplied from the supplying member moves toward the contact part of
the thickness-regulating member, and wherein the supplying member
moves in a direction opposite the direction in which the
developer-carrying member rotates.
6. A process cartridge comprising: the developer cartridge
according to claim 1; and an image-carrying member that receives
developer supplied from the developer-carrying member in the
developer cartridge and carries an electrostatic latent image that
is developed into a developer image by developer supplied from the
developer-carrying member.
7. An image-forming device comprising: the process cartridge
according to claim 6; and a fixing member that fixes the developer
image on a recording medium after the developer image carried on
the image-carrying member in the process cartridge is transferred
onto the recording medium.
8. A developer cartridge comprising: a developer-accommodating
chamber that accommodates developer; at least one window that
detects an amount of developer remaining in the
developer-accommodating chamber; a cleaning member that cleans the
window; an agitating member that stirs the developer accommodated
in the developer-accommodating chamber; and a fixing member
disposed on the agitating member and having a slit formed therein,
the fixing member fixing the cleaning member when the cleaning
member is inserted into the slit.
9. The developer cartridge according to claim 8, wherein the fixing
member comprises a first plate part and a second plate part
opposing each other with the cleaning member interposed
therebetween.
10. The developer cartridge according to claim 8, wherein the
fixing member comprises a plate that opposes the cleaning member
inserted into the slit.
11. The developer cartridge according to claim 9, wherein one of
the first and second plate parts has a protruding part that
protrudes inward in a direction that the first and second plate
parts confront each other; and the cleaning member has a receiving
part for receiving the protruding part.
12. The developer cartridge according to claim 11, wherein the
protruding part has a sloped part that slopes inward in the
direction that the first and second plate parts confront each other
from an upstream to a downstream side in an insertion direction in
which the cleaning member is inserted.
13. The developer cartridge according to claim 11, wherein a
pressing plate is provided on remaining one of the first and the
second plate parts for preventing the cleaning member from floating
off the one of the first and second plate parts provided with the
protruding part.
14. The developer cartridge according to claim 8, wherein the
fixing member further comprises a restricting plate disposed on a
downstream end of the fixing member in the insertion direction for
the cleaning member for restricting movement of the cleaning member
on the downstream side in the insertion direction.
15. The developer cartridge according to claim 14, wherein the
restricting plate has a jig insertion part for inserting a jig to
peel the cleaning member from the first or the second plate part
having the protruding part.
16. The developer cartridge according to claim 8, wherein the
cleaning member is a flexible and elastically deformable
member.
17. A process cartridge comprising: the developer cartridge
according to claim 8 further comprising a developer-carrying member
that carries developer supplied from the developer-accommodating
chamber; and an image-carrying member that is disposed in
confrontation with the developer-carrying member, receives
developer supplied from the developer-carrying member and carries
an electrostatic latent image that is developed into a visible
image by the developer.
18. An image-forming device comprising: the process cartridge
according to claim 17; and a fixing member that fixes a developer
image on a recording medium after the developer image carried on
the image-carrying member has been transferred onto the recording
medium.
19. An image-forming device comprising: the developer cartridge
according to claim 8 further comprising a developer-carrying member
that carries developer supplied from the developer-accommodating
chamber; and an image-carrying member that is disposed in
confrontation with the developer-carrying member, receives
developer supplied from the developer-carrying member and carries
an electrostatic latent image that is developed into a visible
image by the developer.
20. A developer cartridge comprising: a developer-accommodating
chamber that accommodates developer; an agitator that has an
agitator shaft and is disposed inside the developer-accommodating
chamber; and a shaft support unit that supports at least one end of
the agitator shaft, the shaft support unit comprising: a holding
part that is formed as a recess in an inner wall of the
developer-accommodating chamber and rotatably holds the agitator
shaft; a guiding groove that is open on one end and guides the
agitator shaft toward the holding part; and a restricting part that
restricts movement of is the agitator shaft held in the holding
part at a border between the guiding groove and the holding part,
the guiding groove guiding the agitator shaft toward the
restricting part from a position shallower in the inner wall of the
developer-accommodating chamber than the holding part with respect
to the recessed direction of the holding part.
21. The developer cartridge according to claim 20, wherein the
restricting part comprises a sloped surface formed continuously
with a surface of the guiding groove opposing an end of the
agitator shaft and sloping toward the holding part in a direction
away from the surface opposing the end of the agitator shaft.
22. The developer cartridge according to claim 21, wherein a gap
smaller than a diameter of the agitator shaft is formed between the
restricting part and a side surface of the guiding groove that
restricts movement of the agitator shaft in a direction orthogonal
to a guiding direction in which the agitator shaft is guided toward
the holding part.
23. The developer cartridge according to claim 20, further
comprising an introducing surface that slopes toward the guiding
groove from a position deeper than the guiding groove with respect
to the recessed direction and is connected to the open end of the
guiding groove on the surface of the guiding groove opposing the
end of the agitator shaft.
24. The developer cartridge according to claim 20, wherein the
holding part is formed in a polygonal shape in a cross section
taken orthogonal to the agitator shaft.
25. The developer cartridge according to claim 20, wherein the
guiding groove and the holding part have a same width in a
direction orthogonal to a guiding direction for guiding the
agitator shaft.
26. The developer cartridge according to claim 20, further
comprising: a transparent window that transmits a light beam used
in detecting an amount of residual developer in the
developer-accommodating chamber; and a wiper that is attached to
the agitator and cleans the transparent window as the agitator
rotates, wherein the shaft support unit has beveled parts that
contact the wiper.
27. A developer cartridge comprising: a developer-carrying member
having a peripheral surface on which developer is carried; a casing
that has an opening formed therein and supports the
developer-carrying member in an exposed position in the opening,
the opening having an edge; and a reinforcing member that is
substantially formed in a box-shape and is disposed along the edge
of the opening for reinforcing the edge.
28. The developer cartridge according to claim 27, wherein the
reinforcing member forms three sides of a rectangle in a cross
section orthogonal to a direction following a longitudinal edge of
the opening.
29. The developer cartridge according to claim 27, wherein the
developer-carrying member is in a form of a roller having a
rotation axis; and the reinforcing member extends along the
rotation axis of the developing roller.
30. The developer cartridge according to claim 27, further
comprising a film member that is provided on the edge of the
opening and is configured to block a gap between the edge of the
opening and the developer-carrying member in order to prevent
developer from leaking through the gap.
31. The developer cartridge according to claim 30, wherein the edge
of the opening has a step formation including a plurality of steps
in a cross section orthogonal to a direction along the edge of the
opening, and wherein the film member is fixed to a step upstream of
the step farthest downstream in a direction that developer leaks
through the opening so as to be aligned with a downstream edge of
the upstream step.
32. The developer cartridge according to claim 27, wherein the
developer-carrying member is supported in the casing so as to
project out of the casing via the opening formed therein.
33. The developer cartridge according to claim 27, wherein the
casing comprises a guide member that is formed continuously with
the reinforcing member and guides a recording medium while a
developer image formed of developer carried on the
developer-carrying member is transferred onto the recording
medium.
34. The developer cartridge according to claim 33, wherein a
plurality of the guide members is provided, and the guide members
are spaced at intervals in a direction intersecting an extended
direction of the reinforcing member.
35. A process cartridge comprising: the developer cartridge
according to claim 1; and an image-carrying member that is disposed
in opposition to the developer-carrying member, receives developer
supplied from the developer-carrying member, and carries an
electrostatic latent image that is developed into a visible image
by the developer.
36. The process cartridge according to claim 35, wherein the
developer-carrying member is disposed in confrontation with the
image-carrying member in a diagonal direction so that a part of the
developer-carrying member other than the part projecting farthest
out of the casing through the opening formed therein contacts the
image-carrying member.
37. An image-forming device comprising: a process cartridge
receiving portion; and the process cartridge according to claim 35,
wherein the process cartridge is detachably mounted in the process
cartridge receiving portion.
38. The image-forming device comprising: a developer cartridge
receiving portion; and the developer cartridge according to claim
27, wherein the developer cartridge is detachably mounted in the
developer cartridge receiving portion.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priorities to Japanese Patent
Application Nos. 2005-128502 filed on Apr. 26, 2005, 2005-138729
filed on May 11, 2005, 2005-140893 filed on May 13, 2005 and
2005-164321 filed on Jun. 3, 2005, the contents of which are hereby
incorporated by reference into the present application.
TECHNICAL FIELD
[0002] The invention relates generally to an image-forming device,
such as a laser printer, and more particularly, to a developer
cartridge and process cartridge mounted in the image-forming
device.
BACKGROUND
[0003] Conventional electrophotographic image-forming devices such
as laser printers that employ a nonmagnetic, single-component
developing method generally include a photosensitive drum on which
electrostatic latent images are formed, and a developer cartridge
for tribocharging and supplying toner to the photosensitive drum in
order to develop the electrostatic latent image formed thereon.
[0004] One such developer cartridge disclosed in Japanese Patent
Application Publication No. 2000-275948 includes a
toner-accommodating chamber for accommodating the toner, and a
developing chamber for accommodating a supply roller, a developing
roller, and a thickness-regulating blade. A partitioning wall in
which an opening is formed divides the developer cartridge into the
toner-accommodating chamber and the developing chamber.
[0005] This type of developer cartridge also includes an agitator
disposed in the toner-accommodating chamber for stirring toner
therein. The toner stirred by the agitator is discharged toward the
developing chamber through the hole formed in the partitioning
wall. The supply roller supplies the discharged toner onto the
developing roller while the toner is tribocharged between the two
rollers. The thickness-regulating blade scrapes off excess charged
toner carried on the developing roller so that the developing
roller carries a thin layer on the surface thereof.
[0006] A developing device disclosed in Japanese Patent Application
Publication No. 2000-250296 includes transparent windows provided
at opposing two sides of the toner-accommodating chamber for
detecting the amount of residual toner. A cleaning member is
further provided on the agitator for cleaning the windows.
[0007] A developer cartridge disclosed in Japanese Patent
Application Publication No. 2005-24811 supports the shaft of the
agitator with a support part having a hollow groove part and a
restricting part, the hollow groove part having a guiding portion
and a deepest portion. When assembling the agitator, the shaft of
the agitator is guided downward along the guiding portion of the
hollow groove to the deepest portion, passing over the restricting
part, and is maintained in the deepest portion by the restricting
part.
[0008] The above-described conventional developer cartridges have
various disadvantages. One disadvantage is that the charged excess
toner that the thickness-regulating blade scrapes off the surface
of the developing roller accumulates in the developing chamber and
sometimes returns to the toner-accommodating chamber. As the ratio
of previously charged toner to uncharged toner increases, charge
control becomes difficult when tribocharging the toner between the
supply roller and the developing roller, leading to a decline in
image quality. Therefore, it is desirable to supply as much of the
toner that has been previously charged for development as quickly
as possible.
[0009] Another disadvantage is that the number of parts required
for fixing the cleaning member to the agitator increases, making
the assembly process more complex. Further, it is difficult to
cleanly peel off the cleaning member from the agitator for
recycling when the cleaning member has been fixed with double-sided
tape.
[0010] With the above-described structure for supporting the shaft
of the agitator, there is a danger that the shaft could become
damaged when sliding over the restricting part due to a large load
being applied to the shaft when the shaft flexes.
[0011] Still another disadvantage is that by forming the opening in
the casing of the developer cartridge described above for exposing
the developing roller, the peripheral edges of the opening are
inevitably weaker. Hence, when the user grips the casing near the
opening when mounting or removing the developer cartridge, the
casing deforms (flexes), which may cause damage to the developing
roller or force toner out through a gap formed between the
developing roller and the casing.
SUMMARY
[0012] In view of the foregoing, it is an object of the invention
to provide a developer cartridge capable of preventing a decline in
image quality.
[0013] It is another object of the invention to provide a developer
cartridge having a cleaning member fixed to an agitating member
through a simple construction.
[0014] It is still another object of the invention to provide a
developer cartridge that reduces the risk of damage to the shaft of
the agitator when the agitator is mounted in the developer
cartridge.
[0015] It is yet another object of the invention to provide a
developer cartridge having a casing that is reinforced along an
opening therein and that reliably maintains a precise gap between
the developing roller and an edge of the opening.
[0016] It is another object of the invention to provide a process
cartridge and an image-forming device in which the developer
cartridge that attains at least one of the above-described objects
is mounted.
[0017] The above and other others will be attained by a developer
cartridge including:
[0018] a developer-accommodating chamber that accommodates
developer;
[0019] a developer-carrying member that carries developer;
[0020] a supplying member that charges and supplies developer
accommodated in the developer-accommodating chamber to the
developer-carrying member;
[0021] a thickness-regulating member that contacts the
developer-carrying member at a contact part with pressure to
regulate a thickness of developer carried on the developer-carrying
member; and
[0022] a wall having a base end and a distal end and disposed
between the developer-accommodating chamber and the
thickness-regulating member, the distal end of the wall being
positioned closer to the supplying member than the base end of the
wall, the wall partitioning the thickness-regulating member from
the developer-accommodating chamber such that a distance between
the supplying member and the distal end of the wall is shorter than
a distance between the supplying member and the contact part at
which the thickness-regulating member contacts the
developer-carrying member.
[0023] With this construction, the wall provided between the
developer-accommodating chamber and the thickness-regulating member
partitions the thickness-regulating member from the
developer-accommodating chamber. The wall is disposed so that the
distance between the supplying member and the distal end of the
wall is shorter than the distance between the supplying member and
the contact part at which the thickness-regulating member contacts
the developer-carrying member. Therefore, when the
thickness-regulating member scrapes excess developer off the
developer-carrying member to regulate the thickness of developer
carried on the developer-carrying member, this developer remains
between the thickness-regulating member and the wall and can once
again be supplied to the developer-carrying member and regulated by
the pressing contact of the thickness-regulating member. As a
result, since developer scraped off by the thickness-regulating
member, that is, developer carrying a static charge, can be
prevented from returning to the developer-accommodating chamber, it
is possible to control the charge of the developer reliably in
order to prevent a decline in image quality.
[0024] The invention described above can reliably tribocharge the
developer. Further, the supplying member can easily return
previously charged developer to the developer-carrying member,
while also easily supplying uncharged developer accommodated in the
developer-accommodating chamber to the developer-carrying
member.
[0025] According to another aspect of the invention, there is
provided a developer cartridge including:
[0026] a developer-accommodating chamber that accommodates
developer;
[0027] at least one window that detects an amount of developer
remaining in the developer-accommodating chamber;
[0028] a cleaning member that cleans the window;
[0029] an agitating member that stirs the developer accommodated in
the developer-accommodating chamber; and
[0030] a fixing member disposed on the agitating member and having
a slit formed therein, the fixing member fixing the cleaning member
when the cleaning member is inserted into the slit.
[0031] With this construction, by inserting the cleaning member
through the slit in the fixing member, the cleaning member is fixed
to the agitating member via the fixing member. This construction
eliminates the need for extra parts for fixing the cleaning member
and agitating member, enabling the cleaning member to be fixed to
the agitating member through a simple assembly process.
Accordingly, the invention reduces the number of required parts and
improves the efficiency of the assembly operation. Further, since
the cleaning member is fixed to the fixing member by insertion
through the slit, the cleaning member can also be easily removed,
improving the suitability of the cleaning member for recycling.
[0032] According to still another aspect of the invention, there is
provided a developer cartridge including:
[0033] a developer-accommodating chamber that accommodates
developer;
[0034] an agitator that has an agitator shaft and is disposed
inside the developer-accommodating chamber; and
[0035] a shaft support unit that supports at least one end of the
agitator shaft, the shaft support unit comprising: [0036] a holding
part that is formed as a recess in an inner wall of the
developer-accommodating chamber and rotatably holds the agitator
shaft; [0037] a guiding groove that is open on one end and guides
the agitator shaft toward the holding part; and [0038] a
restricting part that restricts movement of the agitator shaft held
in the holding part at a border between the guiding groove and the
holding part, the guiding groove guiding the agitator shaft toward
the restricting part from a position shallower in the inner wall of
the developer-accommodating chamber than the holding part with
respect to the recessed direction of the holding part.
[0039] Since the guiding groove guides the agitator shaft toward
the restricting part from a position shallower in the inner wall
than the holding part in the recessed direction, the agitator shaft
requires less flexing to slide over the restricting part from the
guiding groove when mounting the agitator in the developer
cartridge, thereby reducing the load applied to the agitator shaft
and decreasing the risk of damage to the agitator shaft. Further,
since little force of resistance is applied against the agitator
shaft sliding over the restricting part from the guiding groove,
the agitator shaft can be easily mounted.
[0040] According to yet another aspect of the invention, there is
provided a developer cartridge including:
[0041] a developer-carrying member having a peripheral surface on
which developer is carried;
[0042] a casing that has an opening formed therein and supports the
developer-carrying member in an exposed position in the opening,
the opening having an edge; and
[0043] a reinforcing member that is substantially formed in a
box-shape and is disposed along the edge of the opening for
reinforcing the edge.
[0044] This construction provides the casing with the box-shaped
reinforcing part along the edges of the opening in which the
developer-carrying member is exposed, thereby effectively
reinforcing the edge of the opening, which portion of the casing
has less strength. Further, since the reinforcing part is formed in
a box shape, the thickness of the casing provided with the
reinforcing part can be equivalent to the thickness of the casing
in regions other than the reinforcing part, reducing the likelihood
of sinks forming during the molding process in the surface opposing
the developer-carrying member. Therefore, the opening of the casing
can be reliably reinforced while maintaining a precise gap between
the developer-carrying member and the edge of the opening.
[0045] The construction described above prevents deformation of the
casing when a user grips the casing near the opening, thereby
effectively preventing damage to the developing roller and
preventing developer from leaking through the gap formed between
the developing roller and the casing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0046] The particular features and advantages of present invention
as well as other objects will become apparent from the following
description taken in connection with the accompanying drawings, in
which:
[0047] FIG. 1 is a side cross-sectional view of a laser printer
serving as the image-forming device of the invention;
[0048] FIG. 2A is a side cross-sectional view of a process
cartridge employed in the laser printer shown in FIG. 1;
[0049] FIG. 2B is a side cross-sectional view of another process
cartridge usable in the laser printer shown in FIG. 1 in lieu of
the process cartridge shown in FIG. 2A;
[0050] FIG. 3 is a rear side perspective view of a developer
cartridge according to the invention;
[0051] FIG. 4 is a rear view of the developer cartridge;
[0052] FIG. 5 is a side view of the developer cartridge;
[0053] FIG. 6 is a bottom view of the developer cartridge;
[0054] FIG. 7 is an enlarged side cross-sectional view showing a
lower edge of an opening formed in the casing of the developer
cartridge;
[0055] FIG. 8 is an enlarged side cross-sectional view showing the
lower edge of the opening formed in the casing of a conventional
developer cartridge;
[0056] FIG. 9 is an enlarged side cross-sectional view showing the
lower edge of the opening formed in the casing of FIG. 7 according
to a variation of the illustrative example;
[0057] FIG. 10 is an enlarged side cross-sectional view showing the
lower edge of the opening formed in the casing of FIG. 7 according
to another variation of the illustrative example;
[0058] FIG. 11 is a side cross-sectional view of a developing
chamber employed in the laser printer of FIG. 1;
[0059] FIG. 12 is an enlarged side cross-sectional view showing a
portion of the developing chamber near a supply roller, developing
roller, thickness-regulating blade, and plate wall;
[0060] FIG. 13 is a cross-sectional view of the developer cartridge
along a line A-A in FIG. 11;
[0061] FIG. 14 is a perspective view from the front of the
developer cartridge in FIG. 11 with a top cover in an open
state;
[0062] FIG. 15 is a side cross-sectional view of a developer
cartridge employed in the laser printer of FIG. 1;
[0063] FIG. 16 is a perspective view of an agitator in the
developer cartridge;
[0064] FIG. 17 is a plan view of the agitator;
[0065] FIG. 18 is a cross-sectional view of a portion of the
agitator indicated by the line B-B in FIG. 17;
[0066] FIG. 19 is a cross-sectional view of a portion of the
agitator indicated by the line C-C in FIG. 17;
[0067] FIG. 20 is a perspective view showing an axial end of the
agitator prior to mounting a wiper;
[0068] FIG. 21 is a perspective view showing the axial end of the
agitator after mounting the wiper;
[0069] FIG. 22 is a plan view showing the axial end of the
agitator;
[0070] FIG. 23 is a bottom view showing the axial end of the
agitator;
[0071] FIG. 24A is a cross-sectional view illustrating the process
of assembling the wiper directly after the wiper is inserted into
the slit;
[0072] FIG. 24B is a cross-sectional view illustrating the process
of assembling the wiper as the wiper is inserted farther into the
slit;
[0073] FIG. 24C is a cross-sectional view illustrating the process
of assembling the wiper after the wiper has been completely
inserted into the slit;
[0074] FIG. 25A is a plan view of a wiper according to a variation
of the illustrative example;
[0075] FIG. 25B is a cross-sectional view showing the wiper of FIG.
25A mounted on a fixing member;
[0076] FIG. 26 is a perspective view of the agitator provided with
a guide plate according to a variation of the illustrative
example;
[0077] FIG. 27 is a perspective view inside a
developer-accommodating chamber of the developer cartridge showing
an agitator shaft that is held in a shaft support unit;
[0078] FIG. 28 is a center cross-sectional view of the developer
cartridge without the agitator;
[0079] FIG. 29 is a perspective view showing the shaft support unit
from inside the developer-accommodating chamber when the agitator
shaft has been removed; and
[0080] FIG. 30 is a cross-sectional view of the developer cartridge
along a line D-D in FIG. 28.
DETAILED DESCRIPTION
[0081] A general structure of a laser printer will be described. As
shown in FIG. 1, the laser printer 1 serving as the image-forming
device of the invention includes a main casing 2 and, within the
main casing 2, a feeding unit 4 for supplying sheets of a paper 3,
an image-forming unit 5 for forming images on the paper 3 supplied
by the feeding unit 4.
[0082] (1) Main Casing
[0083] The laser printer 1 also includes an access opening 6 formed
in one side wall of the main casing 2 for inserting and removing a
process cartridge 20 described later, and a front cover 7 capable
of opening and closing over the access opening 6. The front cover 7
is rotatably supported by a cover shaft 8 inserted through a bottom
edge of the front cover 7. Accordingly, when the front cover 7 is
rotated closed about the cover shaft 8, the front cover 7 covers
the access opening 6, as shown in FIG. 1. When the front cover 7 is
rotated open about the cover shaft 8, the access opening 6 is
exposed, enabling the process cartridge 20 to be mounted into or
removed from the main casing 2 via the access opening 6.
[0084] In the following description, the side of the laser printer
1 on which the front cover 7 is mounted and the corresponding side
of the process cartridge 20 when the process cartridge 20 is
mounted in the main casing 2 will be referred to as the "front
side," while the opposite side will be referred to as the "rear
side."
[0085] (2) Feeding Unit
[0086] The feeding unit 4 includes a paper tray 9 that can be
inserted into or removed from a lower section of the main casing 2
in the front-to-rear direction, a separating roller 10 and a
separating pad 11 disposed above a front end of the paper tray 9,
and a feeding roller 12 disposed on the rear side of the separating
roller 10 upstream of the separating pad 11 with respect to the
conveying direction of the paper 3 (hereinafter referred to as the
"paper-conveying direction"). The feeding unit 4 also includes a
paper dust roller 13 disposed above and forward of the separating
roller 10 and downstream of the separating roller 10 in the
paper-conveying direction, and a pinch roller 14 disposed in
opposition to the paper dust roller 13.
[0087] A paper-conveying path for the paper 3 on the feeding end
reverses directions toward the rear side of the laser printer 1,
forming a substantial U-shape near the paper dust roller 13. The
feeding unit 4 also includes a pair of registration rollers 15
disposed below the process cartridge 20 farther downstream of the
U-shaped portion of the paper-conveying path with respect to the
paper-conveying direction.
[0088] A paper-pressing plate 16 is provided inside the paper tray
9 for supporting the paper 3 in a stacked state. The paper-pressing
plate 16 is pivotably supported on the rear end thereof, so that
the front end can pivot downward to a resting position in which the
paper-pressing plate 16 rests on a bottom plate of the paper tray 9
and can pivot upward to a feeding position in which the
paper-pressing plate 16 slopes upward from the rear end to the
front end.
[0089] A lever 17 is provided in the front section of the paper
tray 9 for lifting the front end of the paper-pressing plate 16
upward. The rear end of the lever 17 is pivotably supported on a
lever shaft 18 at a position below the front end of the
paper-pressing plate 16 so that the front end of the lever 17 can
pivot between a level position in which the lever 17 lies along the
bottom plate of the paper tray 9 and a sloped position in which the
front end of the lever 17 lifts the paper-pressing plate 16 upward.
When a driving force is inputted into the lever shaft 18, the lever
17 rotates about the lever shaft 18 and the front end of the lever
17 raises the front end of the paper-pressing plate 16, shifting
the paper-pressing plate 16 into the feeding position.
[0090] When the paper-pressing plate 16 is in the feeding position,
the topmost sheet of paper 3 stacked on the paper-pressing plate 16
is pressed against the feeding roller 12. The rotating feeding
roller 12 begins feeding the sheets of paper 3 toward a separating
position between the separating roller 10 and separating pad
11.
[0091] When the paper tray 9 is removed from the main casing 2, the
paper-pressing plate 16 settles into the resting position. While
the paper-pressing plate 16 is in the resting position, the paper 3
can be stacked on the paper-pressing plate 16.
[0092] When the feeding roller 12 conveys a sheet of the paper 3
toward the separating position and the sheet becomes interposed
between the separating roller 10 and separating pad 11, the
rotating separating roller 10 separates and feeds the paper 3 one
sheet at a time. Each sheet of paper 3 fed by the separating roller
10 passes between the paper dust roller 13 and pinch roller 14.
After the paper dust roller 13 removes paper dust from the sheet of
paper 3, the sheet is conveyed along the U-shaped paper-conveying
path on the feeding end, thereby reversing directions in the main
casing 2, and is conveyed toward the registration rollers 15.
[0093] After registering the paper 3, the registration rollers 15
convey the paper 3 to a transfer position between a photosensitive
drum 28 and a transfer roller 31 described later, at which position
a toner image formed on the photosensitive drum 28 is transferred
onto the paper 3.
[0094] (3) Image-Forming Unit
[0095] The image-forming unit 5 includes a scanning unit 19, the
process cartridge 20, and a fixing unit 21.
[0096] (a) Scanning Unit
[0097] The scanning unit 19 is disposed in a top section of the
main casing 2 and includes a laser light source (not shown), a
polygon mirror 22 that can be driven to rotate, an f.theta. lens
23, a reflecting mirror 24, a lens 25, and a reflecting mirror 26.
The laser light source emits a laser beam based on image data. As
illustrated by a dotted line in FIG. 1, the laser beam is deflected
by the polygon mirror 22, passes through the f.theta. lens 23, is
reflected by the reflecting mirror 24, passes through the lens 25,
and is reflected downward by the reflecting mirror 26 to be
irradiated on the surface of the photosensitive drum 28 in the
process cartridge 20.
[0098] (b) Process Cartridge
[0099] As shown in FIG. 2A, the process cartridge 20 is provided in
the main casing 2 beneath the scanning unit 19 and can be mounted
in or removed from the main casing 2 through the access opening 6.
The process cartridge 20 includes a drum cartridge 27 and a
developer cartridge 30 detachably mounted on the drum cartridge
27.
[0100] The drum cartridge 27 includes a drum side casing 76 and,
within the drum side casing 76, the photosensitive drum 28, a
Scorotron charger 29, the transfer roller 31, and a cleaning member
32.
[0101] Within the drum cartridge 27 are formed a pre-drum opening
113 for conveying the paper 3 to the transfer position inside the
drum cartridge 27, and a post-drum opening 114 for conveying the
paper 3 from the transfer position back out of the drum cartridge
27. The pre-drum opening 113 is provided on the front side of the
transfer position below the developer cartridge 30 to allow
communication between areas inside and outside the drum cartridge
27 along an axial direction of the transfer roller 31 (hereinafter
simply referred to as the "axial direction"). The post-drum opening
114 is formed on the rear side of the transfer position opposing
the pre-drum opening 113 via the transfer position in order to
provide communication between the inside and outside of the drum
cartridge 27 along the axial direction.
[0102] The photosensitive drum 28 includes a main drum body 33 that
is cylindrical in shape and has a positive charging photosensitive
layer formed of polycarbonate or the like on its outer surface, and
a metal drum shaft 34 extending through the center of the main drum
body 33 along the axial direction thereof. The metal drum shaft 34
is supported in the drum cartridge 27, and the main drum body 33 is
rotatably supported relative to the metal drum shaft 34. With this
construction, the photosensitive drum 28 is disposed in the drum
cartridge 27 and is capable of rotating about the metal drum shaft
34. Further, the photosensitive drum 28 is driven to rotate by a
driving force inputted from a motor (not shown).
[0103] The charger 29 is supported on the drum cartridge 27
diagonally above and rearward of the photosensitive drum 28. The
charger 29 opposes the photosensitive drum 28 but is separated a
prescribed distance from the photosensitive drum 28 so as not to
contact the same. The charger 29 includes a discharge wire 35
disposed in opposition to but separated a prescribed distance from
the photosensitive drum 28, and a grid 49 provided between the
discharge wire 35 and the photosensitive drum 28 for controlling
the amount of corona discharge from the discharge wire 35 that
reaches the photosensitive drum 28. By applying a high voltage to
the discharge wire 35 for generating a corona discharge from the
discharge wire 35 at the same time a bias voltage is applied to the
grid 49, the charger 29 can charge the surface of the
photosensitive drum 28 with a uniform positive polarity.
[0104] The developer cartridge 30 includes a casing 36 and, within
the casing 36, a supply roller 37, a developing roller 38, and a
thickness-regulating blade 39. The developer cartridge 30 is
detachably mounted on the drum cartridge 27. Accordingly, when the
process cartridge 20 is mounted in the main casing 2, the developer
cartridge 30 can be mounted in the main casing 2 by first opening
the front cover 7 and subsequently inserting the developer
cartridge 30 through the access opening 6 and mounting the
developer cartridge 30 on the process cartridge 20.
[0105] The casing 36 has a box shape that is open on the rear side,
as will be described later, and has two side walls 69. A
partitioning wall 40 is provided in the casing 36 for partitioning
the interior of the casing 36 into a toner-accommodating chamber 41
and a developing chamber 42. The partitioning wall 40 is disposed
at a position in the casing 36 midway in the front-to-rear
direction for partitioning the interior of the casing 36 in the
front-to-rear direction. An opening 43 is formed through a midway
region of the partitioning wall 40.
[0106] The toner-accommodating chamber 41 occupies a space in the
front side of the casing 36 partitioned by the partitioning wall
40. The toner-accommodating chamber 41 is filled with a
nonmagnetic, single-component toner having a positive charge. The
toner used in the illustrative example is a polymerized toner
obtained by copolymerizing a polymerized monomer using a well-known
polymerization method such as suspension polymerization. The
polymerized monomer may be, for example, a styrene monomer such as
styrene or an acrylic monomer such as acrylic acid, alkyl (C1-C4)
acrylate, or alkyl (C1-C4) meta acrylate. The polymerized toner is
formed as particles substantially spherical in shape in order to
have excellent fluidity for achieving high-quality image
formation.
[0107] This type of toner is compounded with a coloring agent, such
as carbon black, or wax, as well as an additive such as silica to
improve fluidity. The average diameter of the toner particles is
about 6-10 .mu.m.
[0108] Toner detection windows 44 are provided in both side walls
69 of the casing 36 that define the toner-accommodating chamber 41
for detecting the amount of toner remaining in the
toner-accommodating chamber 41. The toner detection windows 44 are
formed in the side walls 69 near the partitioning wall 40 and
oppose each other in the width direction (the direction orthogonal
to the front-to-rear direction and the vertical) across the
toner-accommodating chamber 41. The toner detection windows 44 are
formed by embedding a transparent disc-shaped plate in each side
wall 69.
[0109] An agitator 45 is disposed in the toner-accommodating
chamber 41 for agitating toner accommodated therein. The agitator
45 includes a rotational shaft 46 and an agitating member 47.
[0110] The rotational shaft 46 is rotatably supported in the side
walls 69 substantially in the center of the toner-accommodating
chamber 41. The agitating member 47 is provided on the rotational
shaft 46. A motor (not shown) produces a driving force that is
inputted into the rotational shaft 46 for driving the rotational
shaft 46 to rotate. Consequently, the agitating member 47 moves in
a circular path about the rotational shaft 46 through the
toner-accommodating chamber 41 and stirs toner accommodated in the
toner-accommodating chamber 41. When the agitating member 47 stirs
the toner, some of the toner is discharged in the front-to-rear
direction toward the supply roller 37 through the opening 43 formed
in the partitioning plate 40.
[0111] The agitator 45 also includes wipers 48 attached at both
axial ends of the rotational shaft 46. When the rotational shaft 46
rotates, the wipers 48 move in a circular direction about the
rotational shaft 46 through the toner-accommodating chamber 41 in
order to wipe the toner detection windows 44 provided in the side
walls 69. Hence, the wipers 48 function to clean the toner
detection windows 44.
[0112] The developing chamber 42 occupies an interior space in the
rear side of the casing 36 partitioned by the partitioning wall 40.
The developing chamber 42 accommodates the supply roller 37, the
developing roller 38, and the thickness-regulating blade 39.
[0113] The supply roller 37 is disposed rearward of the opening 43
and includes a metal roller shaft 50 covered by a sponge roller 51
formed of an electrically conductive foam material. The roller
shaft 50 is rotatably supported within the developing chamber 42 in
both side walls 69 of the casing 36. The supply roller 37 is driven
to rotate by a driving force inputted into the roller shaft 50 from
a motor (not shown).
[0114] The developing roller 38 is disposed rearward of the supply
roller 37 and contacts the supply roller 37 with pressure so that
both are compressed. The developing roller 38 includes a metal
roller shaft 52, and a rubber roller 53 formed of an electrically
conductive rubber material that covers the roller shaft 52. The
roller shaft 52 is rotatably supported in both side walls 69 within
the developing chamber 42. The rubber roller 53 is more
specifically formed of an electrically conductive urethane rubber
or silicon rubber containing fine carbon particles, the surface of
which is coated with urethane rubber or silicon rubber containing
fluorine. The developing roller 38 is driven to rotate by a driving
force inputted into the roller shaft 52 from a motor (not shown).
Further, a developing bias is applied to the developing roller 38
during a developing operation.
[0115] When the developer cartridge 30 is mounted in the drum
cartridge 27, the developing roller 38 opposes the photosensitive
drum 28 diagonally from the top front thereof. In other words, the
rear portion of the developing roller 38 below the vertical center
that protrudes farthest rearward contacts the photosensitive drum
28.
[0116] The thickness-regulating blade 39 includes a main blade
member 54 configured of a metal leaf spring, and a pressing part 55
provided on a distal end of the main blade member 54. The pressing
part 55 has a semicircular cross section and is formed of an
insulating silicon rubber. The thickness-regulating blade 39 is
attached to the casing 36. Specifically, a mounting member 109 is
provided for fixing a base end of the main blade member 54 to a
rear end portion of the casing 36.
[0117] A sealing member 110 is interposed between the casing 36 and
mounting member 109 to prevent toner from leaking therethrough.
[0118] The mounting member 109 is provided in the rear section of
the casing 36 and includes a plate-shaped front support member 115,
a back support member 111 having a substantially L-shaped cross
section, and a screw 112. The front support member 115 is disposed
on the rear side of the sealing member 110. The base end of the
main blade member 54 is disposed on the rear side of the front
support member 115, and the back support member 111 is disposed on
the rear side of the base end of the main blade member 54. The
screw 112 is inserted through the back support member 111, the base
end of the main blade member 54, and the front support member 115
and fixes these components together. With the sealing member 110
interposed between the thickness-regulating blade 39 and casing 36,
the thickness-regulating blade 39 is fixed together with the
mounting member 109 to the casing 36 by a screw 130 (see FIGS. 3
and 4) Hence, the main blade member 54 is attached to the casing 36
with the base end of the main blade member 54 interposed between
the front support member 115 and back support member 111. With this
construction, the pressing part 55 disposed on the distal end of
the main blade member 54 contacts the developing roller 38 with
pressure through the elastic force of the main blade member 54.
[0119] Toner discharged through the opening 43 is supplied onto the
developing roller 38 by the rotating supply roller 37. At this
time, the toner is positively tribocharged between the supply
roller 37 and the developing roller 38. As the developing roller 38
rotates, the toner supplied to the surface of the developing roller
38 passes between the rubber roller 53 of the developing roller 38
and the pressing part 55 of the thickness-regulating blade 39,
thereby maintaining a uniform thickness of toner on the surface of
the developing roller 38.
[0120] The cleaning member 32 includes a cleaning brush 58 that
functions to scrape off paper dust and the like deposited on the
photosensitive drum 28.
[0121] As the photosensitive drum 28 rotates, the charger 29
charges the surface of the photosensitive drum 28 with a uniform
positive polarity. Subsequently, a laser beam emitted from the
scanning unit 19 is scanned at a high speed over the surface of the
photosensitive drum 28, forming an electrostatic latent image
corresponding to an image to be formed on the paper 3.
[0122] Next, positively charged toner carried on the surface of the
developing roller 38 comes into contact with the photosensitive
drum 28 as the developing roller 38 rotates and is supplied to
areas on the surface of the positively charged photosensitive drum
28 that were exposed to the laser beam and, therefore, have a lower
potential. In this way, the latent image on the photosensitive drum
28 is transformed into a visible image according to a reverse
developing process so that a toner image is carried on the surface
of the photosensitive drum 28.
[0123] Subsequently, as the registration rollers 15 convey a sheet
of the paper 3 into the drum cartridge 27 via the pre-drum opening
113 and through the transfer position between the photosensitive
drum 28 and transfer roller 31, the toner image carried on the
surface of the surface of the photosensitive drum 28 is transferred
onto the paper 3 by the transfer bias applied to the transfer
roller 31. After the toner image is transferred, the paper 3 is
conveyed out of the drum cartridge 27 via the post-drum opening 114
and is conveyed to the fixing unit 21.
[0124] Toner remaining on the photosensitive drum 28 after the
transfer operation is recovered by the developing roller 38.
Further, paper dust deposited on the photosensitive drum 28 from
the paper 3 is recovered by the cleaning brush 58 of the cleaning
member 32.
[0125] (c) Fixing Unit
[0126] The fixing unit 21 is disposed on the rear side of the
process cartridge 20 and includes a fixed frame 59; and a heating
roller 60 and a pressure roller 61 provided within the fixed frame
59.
[0127] The heating roller 60 includes a metal tube, the surface of
which has been coated with a fluorine resin, and a halogen lamp
disposed inside the metal tube for heating the same. The heating
roller 60 is driven to rotate by a driving force inputted from a
motor (not shown).
[0128] The pressure roller 61 is disposed below and in opposition
to the heating roller 60 and contacts the heating roller 60 with
pressure. The pressure roller 61 is configured of a metal roller
shaft covered with a roller that is formed of a rubber material The
pressure roller 61 follows the rotational drive of the heating
roller 60.
[0129] In the fixing unit 21, a toner image transferred onto the
paper 3 at the transfer position is fixed to the paper 3 by heat as
the paper 3 passes between the heating roller 60 and pressure
roller 61. After the toner image is fixed to the paper 3, the
heating roller 60 and pressure roller 61 continue to convey the
paper 3 along a discharge end paper-conveying path toward a
discharge tray 62 formed on the top surface of the main casing
2.
[0130] The paper-conveying path on the discharge end leads from the
fixing unit 21 to the discharge tray 62 and is substantially
U-shaped for reversing the conveying direction of the paper 3 to a
direction toward the front of the laser printer 1. A pair of
conveying rollers 63 is disposed at a midpoint along the discharge
end paper-conveying path, and a pair of discharge rollers 64 is
disposed at a downstream end of the same path.
[0131] Hence, after passing through the fixing unit 21, the paper 3
is conveyed along the discharge end paper-conveying path, where the
conveying rollers 63 receive and convey the paper 3 to the
discharge rollers 64, and the discharge rollers 64 subsequently
receive and discharge the paper 3 onto the discharge tray 62.
[0132] Next, a structure related to the casing of the developer
cartridge will be described.
[0133] As shown in FIGS. 2A and 3, the casing 36 of the developer
cartridge 30 has a box shape that is open on the rear side and is
integrally provided with a top wall 70, a front wall 72, the two
side walls 69 described above, and a bottom wall 71. The open
region on the rear side is an opening 94.
[0134] As shown in FIG. 3, the opening 94 is defined by the back
support member 111 of the mounting member 109, the rear edges of
the side walls 69, and the rear edge of the bottom wall 71. When
viewed from the rear side, the opening 94 is substantially
rectangular and extends in the width direction. The developing
roller 38 is disposed in the opening 94 and is exposed therefrom.
As shown in FIG. 5, the developing roller 38 is supported on the
casing 36 so as to protrude out of the casing 36 via the opening 94
when viewed from the side. An insertion hole 121 is formed in the
rear end of each side wall 69 of the casing 36 at positions
opposing each other in the width direction. The roller shaft 52 of
the developing roller 38 is inserted through the insertion holes
121 so that the developing roller 38 is rotatably supported on the
casing 36 with a vertical center portion of the rubber roller 53
protruding farthest out of the casing 36 through the opening
94.
[0135] As shown in FIG. 2A, the top wall 70 is plate-shaped in a
plan view and functions to close off the top of the
toner-accommodating chamber 41 and developing chamber 42.
[0136] The front wall 72 is plate-shaped in a front view and
functions to close off the front side of the toner-accommodating
chamber 41. The front wall 72 extends downward from the front edge
of the top wall 70.
[0137] As shown in FIGS. 3 and 5, the side walls 69 are
plate-shaped and function to close off the sides of the
toner-accommodating chamber 41 and developing chamber 42. The side
walls 69 also rotatably support the rotational shaft 46, roller
shaft 50, and roller shaft 52.
[0138] As shown in FIG. 2A, the bottom wall 71 functions to close
off the bottom of the toner-accommodating chamber 41 and developing
chamber 42. The bottom wall 71 is integrally provided with a front
bottom wall 74, a center bottom wall 75, and a rear bottom wall
76.
[0139] The front bottom wall 74 has a substantially semicircular
cross section following the rotational path of the agitator 45 in
the toner-accommodating chamber 41. The center bottom wall 75 is
provided on the rear side of the front bottom wall 74 and has a
substantially semicircular cross section that follows the
peripheral surface of the supply roller 37 in the developing
chamber 42.
[0140] The rear bottom wall 76 is provided on the rear side of the
center bottom wall 75 and has a flanged plate shape that slopes
downward to the rear. The rear edge of the rear bottom wall 76 is a
lower edge 68 that forms the lower edge of the opening 94 extending
in the width direction of the casing 36.
[0141] A handle 77 is provided on the front side of the casing 36
for the user to grip when mounting or removing the developer
cartridge 30 and process cartridge 20. The handle 77 protrudes
forward from the top of the front wall 72 constituting the casing
36.
[0142] As shown in FIG. 3, a gear mechanism (not shown) for driving
the rotational shaft 46, roller shaft 50, and roller shaft 52 to
rotate, and a gear cover 79 for covering the gear mechanism are
provided on one of the side walls 69 constituting the casing 36.
Two partial rear walls 73 are provided on the lower edge 68 in the
opening 94 of the casing 36.
[0143] The partial rear walls 73 are disposed at the widthwise ends
of the lower edge 68 and are spaced apart in the width direction.
The partial rear walls 73 extend upward from both widthwise ends of
the lower edge 68. A bottom portion of each partial rear walls 73
on the widthwise inner side has been cut away to form a substantial
L-shape in a rear view.
[0144] A reinforcing part 80 is provided on the lower edge 68 of
the opening 94.
[0145] The reinforcing part 80 extends along the lower edge 68
between the two partial rear walls 73 and is fitted in the cutout
portions of the partial rear walls 73. The reinforcing part 80 is
formed continuously from the lower edge 68 of the opening 94 and is
integrally provided with a top wall 82, a front wall 85, a bottom
wall 83, and two side walls 84. The reinforcing part 80 is
box-shaped and open on the rear side. Specifically, a cross section
of the reinforcing part 80 taken orthogonal to the width direction
substantially forms three sides of a rectangle with the missing
side on the rear.
[0146] As shown in FIGS. 3 and 7, the top wall 82 is provided along
the lower edge 68 and formed continuously therewith. The top wall
82 protrudes rearward. The front wall 85 is shaped substantially
like an elongated rectangular plate along the lower edge 68 and
extends downward from the front edge of the top wall 82. The bottom
wall 83 also has a substantially elongated rectangular plate shape
extending along the lower edge 68 and is disposed opposite the top
wall 82 in the vertical direction. The bottom wall 83 extends
obliquely downward and rearward from the lower edge of the front
wall 85.
[0147] As shown in FIG. 3, the side walls 84 have a substantially
rectangular plate shape and are disposed on both widthwise ends of
the top wall 82, front wall 85, and bottom wall 83 so as to face
each other in the width direction.
[0148] As shown in FIG. 7, with the front wall 85 linking the front
ends of the top wall 82 and bottom wall 83, a cross section of the
reinforcing part 80 taken orthogonal to the width direction forms
three sides of a rectangle that opens toward the rear. Further, as
shown in FIG. 3, the two side walls 84 connect both widthwise edges
of the top wall 82 to the respective widthwise edges of the front
wall 85 and bottom wall 83, forming a box shape that opens toward
the rear.
[0149] As shown in FIG. 7, the portion of the lower edge 68 above
the reinforcing part 80 is integrally provided with a rear step
part 97 and a front step part 98 disposed diagonally above and
forward of the rear step part 97. With this structure, a cross
section of the lower edge 68 taken orthogonal to the width
direction has a stepped formation.
[0150] The rear step part 97 includes a rear surface 99 and a top
surface 100. The rear surface 99 forms the endface on the rear side
of the top wall 82. The rear surface 99 is a flat vertical surface
in a cross section taken orthogonal to the width direction. The top
surface 100 is provided continuously from the top of the rear
surface 99. In a cross section taken orthogonal to the width
direction, the top surface 100 has a flat plate shape extending
diagonally upward and forward from the rear surface 99.
[0151] The front step part 98 includes a rear surface 101, and a
top surface 102. The rear surface 101 is formed continuously from
the front edge of the top surface 100. In a cross section taken
orthogonal to the width direction, the rear surface 101 is
plate-shaped and extends diagonally upward and rearward from the
front edge of the top surface 100.
[0152] The top surface 102 is formed continuously from the top edge
of the rear surface 101. In a cross section taken orthogonal to the
width direction, the top surface 102 has a plate shape that extends
diagonally upward and forward from the top edge of the rear surface
101.
[0153] A lower film 87 is provided on the top surface 102 of the
lower edge 68. The lower film 87 is formed of a polyethylene
terephthalate film in the shape of a substantially rectangular
sheet. As shown in FIGS. 2 and 7, the rear half of the lower film
87 is fixed to the surface of the top surface 102.
[0154] Specifically, the lower film 87 is disposed so that the rear
edge of the lower film 87 is flush with the rear surface 101 of the
lower edge 68, as shown in FIG. 7. More specifically, using the
rear edge of the top surface 102 (the edge formed by the rear
surface 101 and top surface 102) as a reference for the
front-to-rear direction, the rear half of the lower film 87 is
fixed to the top surface 102 with double-sided tape or the like
(not shown). As a result, the rear endface of the lower film 87 is
positioned flush with the reference in the front-to-rear
direction.
[0155] As shown in FIG. 2A, the lower film 87 is positioned with
the rear half fixed to the top surface 102 and the front half
extending obliquely upward and forward to contact the lower surface
of the developing roller 38. In this way, the lower film 87 blocks
off the gap between the lower edge 68 and the developing roller 38
and prevents toner from leaking through that gap.
[0156] As shown in FIGS. 3 and 6, guide members 81 are provided on
the casing 36 of the developer cartridge 30. The guide members 81
protrude downward from the bottom wall 71 and are plate-shaped,
extending in the front-to-rear direction. The guide members 81 are
disposed parallel to each other at intervals in the width
direction. As shown in FIG. 2A, each guide member 81 protrudes
downward from the rear bottom wall 76 and center bottom wall 75 and
has a rear end 105 connected to the front wall 85 and bottom wall
83, and a front end 104 connected to the front bottom wall 74. Each
guide member 81 is integrally formed with the bottom wall 83, front
wall 85, rear bottom wall 76, center bottom wall 75, and front
bottom wall 74. Each guide member 81 also has a lower edge 106 that
extends straight forward from the rear end of the bottom wall 83
and then gently curves upward and forward below the center bottom
wall 75 to meet the rear end of the front bottom wall 74.
[0157] As shown in FIG. 3, a guide member reinforcing part 86 is
provided for reinforcing the guide members 81. As shown in FIGS. 2A
and 6, the guide member reinforcing part 86 has a plate shape and
extends in the width direction. The guide member reinforcing part
86 protrudes downward from the center bottom wall 75 so as to
intersect a front-to-rear midpoint of each guide member 81 in a
direction substantially orthogonal to the front-to-rear direction.
The guide member reinforcing part 86 couples the guide members 81
in the width direction and reinforces the guide members 81.
[0158] In the developer cartridge 30 of the above-described
illustrative example, the box-shaped reinforcing part 80 open on
the rear is provided along the lower edge 68 of the opening 94. The
reinforcing part 80 effectively reinforces the lower edge 68 of the
opening 94, which is a weak region of the casing 36. By forming the
reinforcing part 80 in a box shape open toward the rear side, it is
possible to form the casing 36 at a uniform thickness in the region
of the reinforcing part 80 and in the regions other than the
reinforcing part 80 to reduce the likelihood of sinks developing
during molding in the surface opposing the developing roller 38
that is formed continuously with the reinforcing part 80, that is,
the top surface 102 of the lower edge 68. Hence, the reinforcing
part 80 can reliably reinforce the opening 94 of the casing 36 and,
moreover, can maintain a precise gap between the developing roller
38 and the lower edge 68 of the opening 94.
[0159] In the developer cartridge 30 of the illustrative example
described above, the cross section of the reinforcing part 80 taken
orthogonal to the width direction has a three-sided rectangular
shape, facilitating removal of the reinforcing part 80 during the
molding process and enabling the reinforcing part 80 to be easily
formed in a box shape. Hence, it is possible to reliably reinforce
the opening 94 of the casing 36, while simplifying the molding
process.
[0160] In the developer cartridge 30 of the illustrative example,
the reinforcing part 80 extends in the width direction of the
developing roller 38, that is, along the width direction of the
casing 36 in the lower edge 68 of the opening 94. The reinforcing
part 80 prevents the casing 36 from deforming when the user grips
the casing 36 near the opening 94, thereby effectively preventing
damage to the developing roller 38 and the occurrence of toner
leaking between the developing roller 38 and casing 36.
[0161] The lower film 87 in the developer cartridge 30 of the
illustrative example blocks off the gap formed between the lower
edge 68 of the opening 94 and the developing roller 38, preventing
toner from leaking through this gap. Further, the reinforcing part
80 provided on the lower edge 68 is formed in a box shape that
makes sinks less likely to occur during molding in the top surface
102 of the lower edge 68 that opposes the developing roller 38. As
a result, the top surface 102 can be formed as a smooth surface,
enabling the lower film 87 to be fixed to the smooth top surface
102 with precision.
[0162] When the lower edge 68 is formed with a simple rectangular
cross section, as in the conventional structure shown in FIG. 8, if
the lower film 87 is fixed to the lower edge 68 by aligning the
rear edge of the lower film 87 with the rear edge of the lower edge
68, as shown by the solid line in FIG. 8, the lower film 87 is
susceptible to peeling off the lower edge 68 should the lower edge
68 contact another component. On the other hand, if the lower film
87 is fixed to a position on the lower edge 68 farther forward than
the rear edge, as indicated by the dotted line in FIG. 8, it is
possible to reduce the risk of the lower film 87 peeling from the
top surface of the lower edge 68, but there is no definite
reference point for fixing the lower film 87 to the lower edge 68.
As a result, it is not possible to fix the lower film 87 reliably
to the lower edge 68 along the width direction, reducing the
mounting precision of the lower film 87.
[0163] However, in the developer cartridge 30 of the illustrative
example, the lower edge 68 has a stepped cross-sectional shape
configured of the rear step part 97 and front step part 98. The
lower film 87 is fixed to the lower edge 68 by aligning the rear
edge of the lower film 87 with the rear edge of the front step part
98 provided farther forward of the rear step part 97, that is, on
the upstream side in the direction that toner leaks through the
opening 94. Therefore, if the rear step part 97 contacts another
component, the lower film 87 is less likely to peel of the top
surface 102 since the lower film 87 is fixed to the front step part
98 disposed in front of the rear step part 97. Moreover, fixing the
lower film 87 on the front step part 98 with the rear edge of the
front step part 98 as a reference point enables the lower film 87
to be fixed reliably along the top surface 102.
[0164] In the developer cartridge 30 of the illustrative example,
the developing roller 38 protrudes out of the casing 36 via the
opening 94. Accordingly, when the developer cartridge 30 is mounted
on the drum cartridge 27, the developing roller 38 can oppose the
photosensitive drum 28 from a position on the top front side so
that a portion of the developing roller 38 below the vertical
center protruding farthest through the opening 94 contacts the
photosensitive drum 28. This construction can enhance the freedom
of setting the device layout, enabling production of a more compact
device. The construction can also allocate space for forming the
reinforcing part 80 on the lower edge 68.
[0165] In the developer cartridge 30 of the illustrative example,
the guide members 81 are formed continuously with the reinforcing
part 80 for guiding the paper 3 to the transfer position between
the photosensitive drum 28 and transfer roller 31 when the paper 3
is conveyed into the drum cartridge 27 through the pre-drum opening
113. Accordingly, the guide members 81 can smoothly guide the paper
3 to the transfer position, while further reinforcing the opening
94 of the casing 36.
[0166] Further, the guide members 81 are formed along the
front-to-rear direction orthogonal to the width direction in which
the reinforcing part 80 extends. The guide members 81 are spaced at
intervals in the width direction. Accordingly, the guide members 81
can reliably guide the paper 3 to the transfer position while
reducing the frictional resistance generated between the paper 3
and the guide members 81.
[0167] The process cartridge 20 and the laser printer 1 of the
illustrative example described above includes the developer
cartridge 30 provided with the reinforcing part 80 for reinforcing
the opening 94 formed in the casing 36. Accordingly, the developer
cartridge 30 enhances the rigidity of both the process cartridge 20
and the laser printer 1.
[0168] In the illustrative example described above, the developer
cartridge 30 is detachably mounted on the drum cartridge 27 to form
the process cartridge 20, and the process cartridge 20 is
detachably mounted in the main casing 2. However, it is also
possible to provide the photosensitive drum 28, charger 29,
transfer roller 31, cleaning member 32, and the like in the main
casing 2, while eliminating the drum cartridge 27, and to
detachably mount the developer cartridge 30 in the main casing
2.
[0169] In the illustrative example described above, the cross
section of the reinforcing part 80 taken orthogonal to the width
direction forms three sides of a rectangle that is open toward the
rear, as shown in FIG. 7. However, the reinforcing part of the
invention need not have this cross-sectional shape, provided that
the reinforcing part has a box shape. For example, the rear edges
of the top wall 82, bottom wall 83, and side walls 84 (not shown in
FIG. 9) may be connected by a rear wall 95, as shown in FIG. 9.
With this construction, the cross section of the reinforcing part
taken orthogonal to the width direction is a closed, hollow
rectangle.
[0170] Alternatively, the reinforcing part 80 may be formed by
connecting the front edges of the top wall 82 and bottom wall 83,
as shown in FIG. 10, so that the cross section of the reinforcing
part taken orthogonal to the width direction forms a V-shape that
opens rearward.
[0171] As shown in FIG. 1, the developer cartridge 30 is detachably
mounted in the drum side casing 76. Accordingly, when the process
cartridge 20 is mounted in the main casing 2, the developer
cartridge 30 can be mounted in the main casing 2 by first opening
the front cover 7 and subsequently inserting the developer
cartridge 30 through the access opening 6 and mounting the
developer cartridge 30 on the process cartridge 20.
[0172] As shown in FIG. 11, the developer cartridge 30 includes a
developer side casing 36 and, within the developer side casing 36,
a developing roller 38, a supply roller 37, a thickness-regulating
blade 39, and a plate wall 49.
[0173] As shown in FIGS. 11 and 14, the developer side casing 36 is
formed in a box shape that is open on the rear side. The developer
side casing 36 includes a top cover 70, and a main casing body 87.
An open portion formed on the rear side is a rear opening 94.
[0174] The rear opening 94 is defined by a back support member 111
of a mounting member 109 described later, and rear edges of side
walls 69 and a bottom wall 71. The rear opening 94 is substantially
rectangular in a rear view and extends in the width direction
(hereinafter, the width direction will signify a direction
orthogonal to the front-to-rear direction and the vertical
direction).
[0175] The top cover 70 is plate-shaped in a plan view and opens
and closes over the top of a toner-accommodating chamber 41 and a
developing chamber 42 described later. The top cover 70 is
integrally formed with an upper portion of a partitioning wall 40
described later, the plate wall 49, and a plurality of
front-to-rear ribs 88 and widthwise ribs 89 described later.
[0176] The front-to-rear ribs 88 are plate-shaped and parallel to
one another, extending in the front-to-rear direction on the top
cover 70 when the top cover 70 is assembled on the main casing body
87 (see FIG. 11). As shown in FIG. 14, the front-to-rear ribs 88
are arranged parallel to one another at intervals in the width
direction on the lower surface of the top cover 70 opposing the
interior of the developer side casing 36. Forward protruding parts
90 are disposed on front ends of two of the front-to-rear ribs 88
that are disposed nearest the widthwise center of the top cover 70
for approaching the front edge of the top cover 70.
[0177] Two of the front-to-rear ribs 88 nearest the widthwise ends
of the top cover 70 are also provided with step parts 91 midway in
the front-to-rear direction. Rearward protruding parts 93
approaching the rear edge of the top cover 70 are provided on the
rear end of these step parts 91, forming a narrow stepped
configuration along the front-to-rear direction. Further, laterally
protruding parts 100 are formed on the front-to-rear ribs 88
nearest the widthwise edges of the top cover 70 protruding outward
in the width direction from the narrow stepped configuration.
[0178] The widthwise ribs 89 are plate-shaped and parallel to one
another, extending in the width direction on the top cover 70 when
the top cover 70 is assembled onto the main casing body 87 (see
FIG. 11). As shown in FIG. 14, the parallel widthwise ribs 89 are
arranged at intervals in the front-to-rear direction on the lower
surface of the top cover 70 facing the interior of the developer
side casing 36 so as to intersect the front-to-rear ribs 88.
[0179] The main casing body 87 is integrally provided with a front
wall 72, the two side walls 69, the bottom wall 71, and a
blade-mounting part 73. A top opening 95 that the top cover 70
covers is formed in the top of the main casing body 87.
[0180] The front wall 72 is plate-shaped in a front view and
functions to close off the front side of the toner-accommodating
chamber 41. As shown in FIG. 11, the front wall 72 extends downward
from the front edge of the top cover 70.
[0181] The side walls 69 are plate-shaped and function to close off
the sides of the toner-accommodating chamber 41 and developing
chamber 42. The side walls 69 also rotatably support an agitator
rotational shaft 46, a supply roller shaft 50, and a developing
roller shaft 52 described later.
[0182] The bottom wall 71 functions to close off the bottom of the
toner-accommodating chamber 41 and developing chamber 42. The
bottom wall 71 is integrally provided with a front bottom wall 77,
a center bottom wall 78, and a rear bottom wall 79.
[0183] The front bottom wall 77 has a substantially semicircular
cross section following the rotational path of an agitator 45
described later in the toner-accommodating chamber 41.
[0184] The center bottom wall 78 is provided on the rear side of
the front bottom wall 77 and has a substantially semicircular cross
section that follows the peripheral surface of the supply roller 37
in the developing chamber 42.
[0185] The rear bottom wall 79 is provided on the rear side of the
front bottom wall 77 and has a flanged plate shape that slopes
downward to the rear.
[0186] The blade-mounting part 73 extends in the width direction,
spanning between upper rear edges of the side walls 69. The
blade-mounting part 73 has a triangular cross section that narrows
toward the bottom. The rear face of the blade-mounting part 73
slopes downward and forward.
[0187] When viewed from the top, the top opening 95 is shaped
similar to the outer edges of a lattice formed by the intersecting
front-to-rear ribs 88 and widthwise ribs 89 on the top cover 70 so
as to fit over these outer edges. Step parts 96 are formed on both
side walls 69 constituting the sides of the top opening 95 for
fitting loosely with the step parts 91 of the two front-to-rear
ribs 88 nearest the outer widthwise edges of the top cover 70 when
the top cover 70 is assembled on the main casing body 87.
[0188] As shown in FIGS. 11 and 14, hook parts formed by the rear
edge of the top cover 70 and each of the rearward protruding parts
93 can engage with edges of the blade-mounting part 73 on the
widthwise ends formed of the top surface and front surface of the
blade-mounting part 73 and having an L-shaped cross section to
position the rear edge of the top cover 70 relative to the rear
edge of the main casing body 87 when assembled. The top cover 70 is
then rotated in the direction of the arrow in FIG. 14 about the
points of engagement between the hook parts and the edge of the
blade-mounting part 73 until the outer edges of the lattice formed
by the intersecting front-to-rear ribs 88 and widthwise ribs 89 are
fitted into the top opening 95 formed in the main casing body 87,
thereby completing the process of assembling the top cover 70 on
the main casing body 87.
[0189] By placing the rearward protruding parts 93 in contact with
the blade-mounting part 73 during this assembly process, the top
cover 70 can be positioned relative to the main casing body 87 on
the rear edge. Further, the top cover 70 can be positioned relative
to the main casing body 87 in the width direction when the
laterally protruding parts 100 provided on the outermost
front-to-rear ribs 88 in the width direction contact the inner
surfaces of the side walls 69 constituting the main casing body 87.
The forward protruding parts 90 provided on front edges of the two
centermost front-to-rear ribs 88 then contact the inner surface of
the front wall 72 constituting the main casing body 87 to position
the top cover 70 relative to the main casing body 87 on the front
side. As a result, the top cover 70 can be assembled on the main
casing body 87 with no play between the two.
[0190] A handle 80 is provided on the front side of the developer
side casing 36 for the user to grip when mounting or removing the
developer cartridge 30 and process cartridge 20. The handle 80
protrudes forward from the top of the front wall 72 constituting
the developer side casing 36.
[0191] A gear mechanism 81 for driving the agitator rotational
shaft 46, supply roller shaft 50, and developing roller shaft 52 to
rotate, and a gear cover 82 for covering the gear mechanism 81 are
provided on one of the side walls 69 constituting the developer
side casing 36.
[0192] The partitioning wall 40 is provided in the developer side
casing 36 for partitioning the interior of the developer side
casing 36 into the toner-accommodating chamber 41 and the
developing chamber 42.
[0193] The partitioning wall 40 is disposed at a position in the
developer side casing 36 midway in the front-to-rear direction for
partitioning the interior of the developer side casing 36 in the
front-to-rear direction. An opening 43 penetrates a midway region
of the partitioning wall 40 to allow communication between the
toner-accommodating chamber 41 and developing chamber 42. The lower
portion of the partitioning wall 40 is formed from the connecting
parts of the front bottom wall 77 and center bottom wall 78. The
upper portion of the partitioning wall 40 is formed on the top
cover 70 in the width direction so as to oppose the lower portion
of the partitioning wall 40 vertically with the opening 43 formed
therebetween. The partitioning wall 40 extends vertically downward
from the top cover 70 with a base end of the partitioning wall 40
connected to the top cover 70 at a position in the front-to-rear
direction of the top cover 70 substantially equivalent to the step
parts 91.
[0194] As shown in FIG. 11, the toner-accommodating chamber 41
occupies a space in the front side of the casing 36 partitioned by
the partitioning wall 40. The toner-accommodating chamber 41 is
filled with a nonmagnetic, single-component toner having a positive
charge.
[0195] Toner supply openings for filling the toner-accommodating
chamber 41 with toner are formed in both side walls 69 of the
developer side casing 36 that define the toner-accommodating
chamber 41. The toner supply openings are sealed with caps 35.
[0196] Toner detection windows 44 are provided in both side walls
69 of the casing 36 that define the toner-accommodating chamber 41
for detecting the amount of toner remaining in the
toner-accommodating chamber 41. The toner detection windows 44 are
formed in the side walls 69 near the partitioning wall 40 and
oppose each other in the width direction across the
toner-accommodating chamber 41. The toner detection windows 44 are
formed by embedding a transparent disc-shaped plate in each side
wall 69.
[0197] An agitator 45 is disposed in the toner-accommodating
chamber 41 for agitating toner accommodated therein. The agitator
45 includes a rotational shaft 46 and an agitating member 47. The
rotational shaft 46 is rotatably supported in the side walls 69
substantially in the center of the toner-accommodating chamber 41.
The agitating member 47 is provided on the rotational shaft 46. A
motor (not shown) produces a driving force that is inputted into
the rotational shaft 46 for driving the rotational shaft 46 to
rotate.
[0198] The agitator 45 also includes wipers 48 attached at both
axial ends of the rotational shaft 46. When the rotational shaft 46
rotates, the wipers 48 move in a circular direction about the
rotational shaft 46 through the toner-accommodating chamber 41 in
order to wipe the toner detection windows 44 provided in the side
walls 69. Hence, the wipers 48 function to clean the toner
detection windows 44.
[0199] The developing chamber 42 occupies an interior space in the
rear side of the casing 36 partitioned by the partitioning wall 40.
The developing chamber 42 accommodates the supply roller 37, the
developing roller 38, and the thickness-regulating blade 39 and is
provided with the plate wall 49.
[0200] The supply roller 37 is disposed rearward of the opening 43
above the center bottom wall 78 of the developing chamber 42. The
supply roller 37 opposes the developing roller 38 diagonally from
the lower front side so that the top of the supply roller 37 is
lower than the top edge of the lower portion of the partitioning
wall 40.
[0201] The supply roller 37 includes a metal roller shaft 50
covered by a sponge roller 51 formed of an electrically conductive
foam material. The supply roller 37 is supported in the side walls
69 of the developer side casing 36 in contact with the developing
roller 38 so that both are compressed to a degree. Specifically,
through-holes 122 are provided in each of the side walls 69 at
positions opposing each other in the width direction. The supply
roller shaft 50 is inserted into the through-holes 122 so that the
supply roller 37 is rotatably supported in the developer side
casing 36.
[0202] A driving force from a motor (not shown) is inputted into
the supply roller shaft 50 for driving the supply roller 37 to
rotate. The supply roller 37 rotates counterclockwise in FIG. 11 so
that the peripheral surface of the supply roller 37 moves in the
opposite direction of the developing roller 38 at the point of
contact between the two rollers.
[0203] The developing roller 38 is disposed above the rear bottom
wall 79 of the developing chamber 42 on the opposite side of the
supply roller 37 from the toner-accommodating chamber 41 in the
front-to-rear direction, that is, rearward of the supply roller 37.
The developing roller 38 opposes the supply roller 37 diagonally
from the upper rear side and contacts the supply roller 37 with
pressure.
[0204] The developing roller 38 is disposed so that substantially
the upper half of the developing roller 38 is above the top of the
supply roller 37. The developing roller 38 has a larger diameter
than the supply roller 37 and includes the metal developing roller
shaft 52 mentioned above, and a rubber roller 53 formed of an
electrically conductive rubber material that covers the developing
roller shaft 52. The rubber roller 5.3 is more specifically formed
of an electrically conductive urethane rubber or silicon rubber
containing fine carbon particles or the like, the surface of which
is coated with urethane rubber or silicon rubber containing
fluorine. The developing roller shaft 52 is supported in the side
walls 69 of the developer side casing 36 within the developing
chamber 42.
[0205] The developing roller 38 is supported in the side walls 69
so as to protrude out of the developer side casing 36 through the
rear opening 94. More specifically, through-holes 121 are formed in
both side walls 69 of the developer side casing 36 at positions
near the rear end thereof so as to oppose each other in the width
direction. The developing roller shaft 52 is inserted through the
through-holes 121 so that the developing roller 38 is rotatably
supported in the developer side casing 36 with a vertical center
portion of the rubber roller 53 protruding farthest out of the
developer side casing 36 through the rear opening 94.
[0206] The developing roller 38 is driven to rotate
counterclockwise in FIG. 11 by a driving force inputted into the
developing roller shaft 52 from a motor (not shown). Further, a
developing bias is applied to the developing roller 38 during a
developing operation.
[0207] The thickness-regulating blade 39 is disposed in the
developing chamber 42 above the developing roller 38 and rearward
of the plate wall 49 described later. The blade-mounting part 73
supported on the rear side of the side walls 69 holds the
thickness-regulating blade 39 at both widthwise ends thereof.
[0208] The thickness-regulating blade 39 includes a main blade
member 54 configured of a metal leaf spring that is rectangular in
a front view (see FIG. 13), and a pressing part 55 provided on a
distal end of the main blade member 54. The main blade member 54
includes an upper end 83, which is a base end mounted in the
blade-mounting part 73, and a lower end 84, which is the distal end
on which the pressing part 55 is provided. The pressing part 55 has
a semicircular cross section and is formed of an insulating silicon
rubber.
[0209] As shown in FIG. 13, the thickness-regulating blade 39
extends in the width direction along the rear face of the
blade-mounting part 73. As shown in FIG. 11, the mounting member
109 fixes the upper end 83 of the main blade member 54 to the rear
face of the blade-mounting part 73 supported in the rear end of the
side walls 69 at both widthwise ends thereof.
[0210] A sealing member 110 is interposed between the rear face of
the blade-mounting part 73 and the mounting member 109 to prevent
toner from leaking therethrough.
[0211] The mounting member 109 includes a plate-shaped front
support member 115, the back support member 111 having a
substantially L-shaped cross section, and a screw 112. The front
support member 115 is disposed on the rear side of the sealing
member 110. The upper end 83 of the main blade member 54 is
disposed on the rear side of the front support member 115, and the
back support member 111 is disposed on the rear side of the upper
end 83. The screw 112 is inserted through the back support member
111, the upper end 83 of the main blade member 54, and the front
support member 115 in the front-to-rear direction for fixing these
components together. A screw 130 fixes the upper end 83 of the main
blade member 54 together with the mounting member 109 to the
blade-mounting part 73 with the sealing member 110 interposed
therebetween.
[0212] Hence, the main blade member 54 is disposed such that the
upper end 83 is supported on the rear face of the blade-mounting
part 73, which slopes obliquely downward to the front, and the
lower end 84 in turn extends diagonally downward toward the front
from the upper end 83 to the supply roller 37, approaching the
developing roller 38 and plate wall 49 therebetween. Accordingly,
the thickness-regulating blade 39 extends downward and forward from
the upper end 83 to the lower end 84 while gradually approaching
the plate wall 49.
[0213] The pressing part 55 extends in the width direction along
the rear surface on the lower end 84 of the main blade member 54.
The pressing part 55 is urged rearward by the elastic force of the
main blade member 54 to contact the rubber roller 53 of the
developing roller 38 with pressure at a position above and slightly
rearward of the point of contact between the developing roller 38
and supply roller 37.
[0214] The plate wall 49 is integrally formed with the top cover 70
and is disposed in the developing chamber 42 above the supply
roller 37 and between the thickness-regulating blade 39 and
partitioning wall 40 in the front-to-rear direction. As shown in
FIG. 13, the plate wall 49 has a rectangular plate shape in a front
view, extending through the developing chamber 42 in the width
direction so as to partition the thickness-regulating blade 39 from
the toner-accommodating chamber 41. The plate wall 49 includes a
base end 85, which is the upper end, and a free end 86, which is
the lower end.
[0215] The base end 85 of the plate wall 49 is connected to the
bottom surface of the top cover 70 between the upper portion of the
partitioning wall 40 and the blade-mounting part 73. The free end
86 of the plate wall 49 extends vertically downward from the base
end 85 toward the supply roller 37. In the front-to-rear direction,
the free end 86 of the plate wall 49 is positioned between a
contact part X at which the pressing part 55 of the
thickness-regulating blade 39 contacts the developing roller 38
(see FIG. 12) and the front edge of the supply roller 37.
Specifically, the base end 85 of the plate wall 49 is vertically
aligned with the sponge roller 51 of the supply roller 37.
[0216] Accordingly, the plate wall 49 extends vertically downward
from the upper end to the lower end so that the free end 86
approaches the pressing part 55 of the thickness-regulating blade
39 and the supply roller 37. With respect to the vertical
direction, the free end 86 of the plate wall 49 extends below the
pressing part 55 and is separated from the supply roller 37.
Further, the upper end 83 and base end 85 of the
thickness-regulating blade 39 and plate wall 49, respectively, are
supported on the top cover 70 and the respective lower end 84 and
free end 86 extend toward the supply roller 37. Accordingly, the
top cover 70, thickness-regulating blade 39, and plate wall 49 form
a substantially rectangular shape in a cross section that grows
narrow toward the bottom (that is, toward the supply roller 37).
Here, the lower end 84 of the thickness-regulating blade 39 and the
free end 86 of the plate wall 49 are separated slightly in the
front-to-rear direction.
[0217] As shown in FIG. 12, the free end 86 of the plate wall 49 is
positioned so that a shortest distance A between the free end 86 of
the plate wall 49 and the surface of the sponge roller 51 on the
supply roller 37 is shorter than a shortest distance B between the
contact part X at which the pressing part 55 of the
thickness-regulating blade 39 contacts the developing roller 38 and
the surface of the sponge roller 51.
[0218] Therefore, as shown in FIG. 13, the free end 86 of the plate
wall 49 is positioned lower than the contact part X at which the
pressing part 55 of the thickness-regulating blade 39 contacts the
developing roller 38.
[0219] When a driving force is inputted into the agitator
rotational shaft 46 from a motor (not shown), the agitator
rotational shaft 46 is driven to rotate clockwise in FIG. 11 so
that the agitating member 47 moves through the toner-accommodating
chamber 41 in a circular direction around the agitator rotational
shaft 46. In this way, the agitating member 47 stirs toner
accommodated in the toner-accommodating chamber 41 and discharges
some of the toner toward the developing chamber 42 via the opening
43.
[0220] Toner discharged toward the developing chamber 42 through
the opening 43 is supplied onto the developing roller 38 by the
rotating supply roller 37. At this time, the toner is positively
tribocharged between the supply roller 37 and developing roller 38
since the surfaces of the two rollers move in opposite directions
at the point of contact. As the developing roller 38 rotates, toner
supplied from the supply roller 37 onto the developing roller 38
moves upward over the side of the supply roller 37 to the contact
part X at which the pressing part 55 of the thickness-regulating
blade 39 contacts the developing roller 38. At this contact part X,
the toner passes between the pressing part 55 of the
thickness-regulating blade 39 and the rubber roller 53 of the
developing roller 38. At this time, the pressing part 55 scrapes
off the excess portion of toner in order to maintain a thin layer
of uniform thickness on the surface of the rubber roller 53.
[0221] In the developer cartridge 30 described above, the plate
wall 49 is disposed between the thickness-regulating blade 39 and
partitioning wall 40 and above the supply roller 37 for
partitioning the thickness-regulating blade 39 from the
toner-accommodating chamber 41. The free end 86 of the plate wall
49 is positioned such that the shortest distance A between the free
end 86 of the plate wall 49 and the sponge roller 51 of the supply
roller 37 is shorter than the shortest distance B between the
contact part X at which the pressing part 55 of the
thickness-regulating blade 39 contacts the developing roller 38 and
the sponge roller 51 of the supply roller 37.
[0222] Toner is positively tribocharged between the supply roller
37 and developing roller 38 that rotate in the same direction so
that the surfaces of the rollers at move in opposite directions in
the area of contact. As the developing roller 38 rotates, some of
the charged toner reaches the contact part X. At this time, the
thickness-regulating blade 39 scrapes off the excess charged toner
to form a thin layer of uniform thickness on the developing roller
38. The excess toner scraped off by the thickness-regulating blade
39 can be maintained between the thickness-regulating blade 39 and
plate wall 49 and can once again be carried on the surface of the
developing roller 38 and regulated by the thickness-regulating
blade 39.
[0223] As a result, since excess charged toner scraped off by the
thickness-regulating blade 39 can be prevented from returning to
the toner-accommodating chamber 41, it is possible to control the
charge of the toner reliably to prevent a decline in image
quality.
[0224] Further, in the developer cartridge 30 of the illustrative
example, the partitioning wall 40 is disposed midway in the
developer side casing 36 in the front-to-rear direction for
partitioning the developer side casing 36 into the
toner-accommodating chamber 41 and developing chamber 42, and the
plate wall 49 is disposed in the developing chamber 42. Hence, the
partitioning wall 40 can prevent excess charged toner scraped off
by the thickness-regulating blade 39 from returning to the
toner-accommodating chamber 41 when the toner flows from the region
between the thickness-regulating blade 39 and plate wall 49.
[0225] Hence, charged toner can be maintained in the developing
chamber 42, thereby further preventing charged toner from returning
to the toner-accommodating chamber 41. As a result, it is possible
to control the charge of the toner more reliably and to further
prevent a decline in image quality.
[0226] Further, the plate wall 49 is arranged so that the base end
85 is connected to the top cover 70 of the developer side casing
36, and the free end 86 is disposed between the contact part X at
which the pressing part 55 of the thickness-regulating blade 39
contacts the developing roller 38 and the front side of the supply
roller 37 in the front-to-rear direction.
[0227] With this construction, even when the excess charged toner
scraped off by the thickness-regulating blade 39 flows along the
plate wall 49 and forward from the free end 86 of the plate wall
49, the charged toner comes into contact with the supply roller 37,
which again supplies the toner to the developing roller 38. Hence,
charged toner is reliably kept between the thickness-regulating
blade 39 and plate wall 49 through a simple construction, thereby
reliably preventing the charged toner from returning to the
toner-accommodating chamber 41.
[0228] In the developer cartridge 30 of the illustrative example,
the thickness-regulating blade 39 gradually approaches the plate
wall 49 from the upper end 83 to the lower end 84, and the pressing
part 55 disposed on the lower end 84 pressingly contacts the rubber
roller 53 of the developing roller 38 through the elastic force of
the main blade member 54. Hence, this simple construction can
reliably prevent excess charged toner scraped off by the pressing
part 55 of the thickness-regulating blade 39 at the contact part X
from flowing past the free end 86 of the plate wall 49 toward the
toner-accommodating chamber 41, thereby further preventing charged
toner from returning to the toner-accommodating chamber 41.
[0229] Further, in the developer side casing 36 described above,
intersecting front-to-rear ribs 88 and widthwise ribs 89 are
provided on the top cover 70 to form a lattice structure. In
addition, the forward protruding parts 90 approaching the front
edge of the top cover 70 are disposed on front ends of the two
front-to-rear ribs 88 nearest the widthwise center of the top cover
70, and step parts 91 and laterally protruding parts 100 are
provided on the two front-to-rear ribs 88 nearest the outer
widthwise edges of the top cover 70, while rearward protruding
parts 93 are disposed on the rear ends of the two front-to-rear
ribs 88.
[0230] With this construction, the outermost edges of the lattice
formed by the intersecting front-to-rear ribs 88 and widthwise ribs
89 are fitted into the top opening 95 so that the forward
protruding parts 90, laterally protruding parts 100, and rearward
protruding parts 93 contact corresponding inner surfaces of the top
opening 95. Accordingly, the top cover 70 can be mounted on the
main casing body 87 with precision so that the plate wall 49
provided on the top cover 70 can be accurately disposed at a
desired position in the developer side casing 36.
[0231] The rearward protruding parts 93 disposed on the rear ends
of the two front-to-rear ribs 88 nearest the widthwise edges of the
top cover 70 contact widthwise ends of the blade-mounting part 73
at positions where the blade-mounting part 73 is supported on the
side walls 69, that is, positions having a high rigidity with
respect to the widthwise center. Therefore, this construction
achieves stable positioning, improving the precision for assembling
the top cover 70 on the main casing body 87.
[0232] Further, the forward protruding parts 90 disposed on the
front ends of the two front-to-rear ribs 88 nearest the widthwise
center of the top cover 70 contact the front wall 72 near the
widthwise center of the front wall 72 where the front wall 72 has
less rigidity and is more likely to flex than at the ends of the
front wall 72 supported by the side walls 69. Therefore, this
structure can prevent flexing in the widthwise center of the gear
cover 82.
[0233] While dimension control must be executed rigorously at the
areas of contact between the top cover 70 and main casing body 87,
efforts to achieve this control cannot be reduced since the control
is local, as described above.
[0234] In the developer cartridge 30 of the illustrative example,
the toner can be reliably tribocharged since the surface of the
supply roller 37 moves in a direction opposite the surface of the
developing roller 38 at the region of contact with the developing
roller 38. Further, the developing roller 38 rotates so that toner
supplied from the supply roller 37 moves rearward on the upper half
of the developing roller 38 so that the toner moves upward over the
side of the supply roller 37 to reach the contact part X at which
the pressing part 55 of the thickness-regulating blade 39 contacts
the developing roller 38. Hence, since the surface of the supply
roller 37 moves opposite the surface of the developing roller 38 at
the region of contact therebetween, the surface of the supply
roller 37 also moves rearward in the upper half thereof.
Accordingly, the supply roller 37 can easily return excess charged
toner that has been scraped off by the thickness-regulating blade
39 to the developing roller 38, while the supply roller 37 can also
easily supply uncharged toner accommodated in the
toner-accommodating chamber 41 to the developing roller 38.
[0235] The process cartridge 20 and the laser printer 1 of the
illustrative example includes the developer cartridge 30 that is
capable of preventing a decline in image quality by preventing
excess charged toner scraped off by the thickness-regulating blade
39 from returning to the toner-accommodating chamber 41 in order to
control the charge of the toner reliably. Accordingly, the process
cartridge 20 and the laser printer 1 can accurately develop
electrostatic latent images formed on the photosensitive drum 28 in
order to form toner images with accuracy and, hence, can achieve
high-quality image formation.
[0236] In the illustrative example described above, the developer
cartridge 30 is detachably mounted on the drum cartridge 27 to form
the process cartridge 20, and the process cartridge 20 is
detachably mounted in the main casing 2. However, it is also
possible to provide the photosensitive drum 28, charger 29,
transfer roller 31, cleaning member 32, and the like in the main
casing 2, while eliminating the drum cartridge 27, and to
detachably mount the developer cartridge 30 in the main casing 2.
It is also possible to eliminate both the drum cartridge 27 and
developer cartridge 30 and to provide the photosensitive drum 28,
charger 29, transfer roller 31, cleaning member 32, and the like in
the main casing 2, as well as the toner-accommodating chamber 41,
developing roller 38, supply roller 37, thickness-regulating blade
39, and plate wall 49.
[0237] Toner detection windows 44 are formed in both side walls 88
of the casing 36 for detecting the amount of toner remaining in the
toner-accommodating chamber 41. The toner detection windows 44 are
formed at positions in the side walls 88 near the partitioning wall
40 and oppose each other in the width direction. The toner
detection windows 44 are transparent discs that are embedded into
the side walls 88 of the casing 36.
[0238] A toner sensor (not shown) including a light-emitting
element and a light-receiving element is disposed on the outer
sides of the casing 36 opposing the toner detection windows 44. The
light-emitting element emits a detection light into the
toner-accommodating chamber 41 through one of the toner detection
windows 44. After passing through the toner-accommodating chamber
41, the detection light exits through the other toner detection
window 44 and is received by the light-receiving element. The toner
sensor is configured to detect the amount of toner remaining in the
toner-accommodating chamber 41 by measuring a detection time during
which the detection light passes through both toner detection
windows 44 while an agitator 45 described below stirs the toner in
the toner-accommodating chamber 41.
[0239] Next, the agitator 45 and wipers 48 according to one
illustrative example will be described in detail while referring to
FIGS. 16 through 24C.
[0240] In addition to the rotational shaft 46, agitating member 47,
and grid 49 described above, the agitator 45 also includes a
light-blocking plate 89 and a guide plate 90, as shown in FIG.
16.
[0241] The agitating member 47 includes a film support member 65
extending radially outward from the rotational shaft 46, and a film
66 mounted on the film support member 65. The film support member
65 includes a plurality of cross plates 68 spaced at intervals from
each other in the width direction of the rotational shaft 46, and a
film support plate 69 linked to the rotational shaft 46 via the
cross plates 68. Each cross plates 68 has a base end connected to
the rotational shaft 46 and extends radially outward therefrom.
[0242] The film support plate 69 extends parallel to and is
separated a prescribed distance from the rotational shaft 46 and is
linked to the distal end of each cross plate 68. Hence, the
rotational shaft 46, cross plates 68, and film support plate 69 are
linked to form a ladder-like structure.
[0243] The film 66 has a base edge fixed to the film support plate
69 along the width direction of the rotational shaft 46. As shown
in FIG. 17, the film 66 is divided into sloped pieces 70 disposed
on both ends in the width direction (identical to the width
direction of the rotational shaft 46) whose free edges are sloped
with respect to the width direction, and a rectangular piece 71
forming a center portion interposed between the two sloped pieces
70, whose free end is shorter than the sloped pieces 70 and aligned
with the width direction.
[0244] As shown in FIG. 16 the film 66 is fixed to the film support
plate 69 at a prescribed obtuse angle with respect to the extended
direction of the cross plates 68. As shown in FIG. 17, the
light-blocking plate 89 is integrally formed with the cross plate
68 positioned just inside the outermost cross plate 68 in the width
direction on one widthwise end of the rotational shaft 46. As shown
in FIG. 16, the light-blocking plate 89 has a plate shape and
extends in a plane orthogonal to the axial direction of the
rotational shaft 46. The light-blocking plate 89 functions to block
at regular intervals the detection light emitted by the toner
sensor for enhancing the precision for detecting residual
toner.
[0245] The guide plate 90 extends radially outward from the
rotational shaft 46 in the direction opposite the direction of the
film 66. The guide plate 90 has a substantially rectangular plate
shape of uniform thickness and is formed in an axial center region
of the rotational shaft 46, extending in a direction opposite the
extended direction of the cross plates 68. When the agitator 45
rotates, the guide plate 90 functions to evenly distribute toner in
the toner-accommodating chamber 41 in the width direction thereof,
and scrapes up toner such that the toner flows toward both
widthwise ends of the toner-accommodating chamber 41.
[0246] The fixing members 49 are disposed one on each widthwise end
of the rotational shaft 46. As shown in FIG. 7, each fixing member
49 is integrally configured of a support plate 72, a gripping plate
73, a connecting wall 74, and a restricting plate 75. Each support
plate 72 has a substantially rectangular plate shape in a plan
view. The support plates 72 are separated a prescribed distance
from the guide plate 90 in the width direction of the rotational
shaft 46 (see FIG. 4) and extend in a direction opposite the
extended direction of the cross plates 68.
[0247] As shown in FIG. 23, a first cutout part 76 is formed in the
support plate 72. The first cutout part 76 is substantially
U-shaped in a bottom view. The first cutout part 76 is formed in a
portion of the support plate 72 opposing the gripping plate 73
along an extended direction in which the support plate 72 extends
from the rotational shaft 46. The first cutout part 76 extends from
a downstream end in the insertion direction for the wipers 48 (an
inside end in the axial direction of the rotational shaft 46)
toward an upstream end in the insertion direction (toward the
outside in the axial direction of the rotational shaft 46). Here,
the extended direction includes both the direction from a base end
of the support plate 72 connected to the rotational shaft 46 toward
the free end of the support plate 72 and the direction from the
distal end to the base end.
[0248] As shown in FIGS. 20 and 22, the first cutout part 76
surrounds a center part 77 of the support plate 72. A boss 78
disposed on the center part 77 protrudes inward in the direction
that the support plate 72 opposes the gripping plate 73.
[0249] The boss 78 is disposed on an upstream end of the center
part 77 in the insertion direction and has a sloped surface 86
formed on the end thereof. The sloped surface 86 slopes inward in
the direction that the support plate 72 opposes the gripping plate
73 from the upstream side toward the downstream side in the
insertion direction.
[0250] As shown in FIGS. 18 and 19, the gripping plate 73 spans
from a midpoint in the extended direction of the support plate 72
to the distal end thereof and opposes the support plate 72 across a
gap corresponding to the thickness of the wiper 48.
[0251] As shown in FIGS. 20 and 22, the gripping plate 73 is formed
in a portion opposing the first cutout part 76 and is substantially
U-shaped in a plan view, nearly identical in shape to the first
cutout part 76. A second cutout part 79 is formed in a region of
the gripping plate 73 opposing the center part 77 formed in the
support plate 72 and is encompassed by the gripping plate 73.
[0252] A portion of the gripping plate 73 extending in the extended
direction of the support plate 72 along the upstream side of the
second cutout part 79 in the insertion direction serves as a
pressing plate 80. The pressing plate 80 functions to prevent the
wiper 48 from floating off the support plate 72.
[0253] The connecting walls 74 run parallel to each other in the
insertion direction and are separated from each other in the
extended direction of the support plate 72 by a prescribed gap
corresponding to the width of the wiper 48. The connecting walls 74
link the support plate 72 to both ends of the gripping plate 73 in
the extended direction.
[0254] With this construction, a slit 81 for receiving the wiper 48
is formed in the fixing member 49 and is defined by the support
plate 72, the gripping plate 73, and the connecting walls 74.
[0255] The restricting plate 75 is disposed along the downstream
end of the support plate 72 with respect to the insertion direction
and extends in the extended direction of the support plate 72. The
restricting plate 75 protrudes from the support plate 72 toward the
area encompassed by the gripping plate 73 and links the support
plate 72 and gripping plate 73 in a region that the support plate
72 opposes the gripping plate 73.
[0256] A jig insertion part 82 is provided as a cutout portion in
the restricting plate 75, forming a gap in the extended direction
of the support plate 72 so that the support plate 72 is in
communication with the center part 77. A depression 83 that is
U-shaped in a plan view is formed in a portion of the support plate
72 in communication with the jig insertion part 82.
[0257] The rotational shaft 46, film support member 65 of the
agitating member 47, fixing members 49, light-blocking plate 89,
and guide plate 90 of the agitator 45 are integrally formed of a
hard synthetic resin such as an ABS resin, while the film 66 is a
flexible film formed of a resin, such as polyethylene
terephthalate.
[0258] As shown in FIG. 20, the wiper 48 is plate-shaped and
substantially rectangular in a plan view. The wiper 48 is formed of
a flexible elastic member, such as urethane rubber.
[0259] As shown in FIG. 19, the wiper 48 is formed with
substantially the same width (dimension of the wiper 48 in a
direction orthogonal to the insertion direction and the thickness
direction) as the width in the extended direction of the slit 81
formed in the fixing member 49. The thickness of the wiper 48 is
substantially the same as the width of the opening formed by the
slit 81 in the direction that the support plate 72 confronts the
gripping plate 73, as shown in FIGS. 18 and 19. The length of the
wiper 48 in the insertion direction is longer than the depth of the
slit 81 in the insertion direction by about two times, as shown in
FIGS. 18 and 21.
[0260] The wiper 48 has a through-hole 84 with a circular cross
section formed therein. When the wiper 48 is inserted into the slit
81 formed in the fixing member 49, the through-hole 84 formed in
the wiper 48 is positioned at the boss 78 for receiving the boss 78
therein.
[0261] Next, a process of mounting the wiper 48 in the fixing
member 49 will be described with reference to FIGS. 7, 8, and
11.
[0262] As illustrated in FIG. 20, the wiper 48 is positioned
opposite the slit 81 and inserted into the slit 81 in the direction
of the arrow. FIGS. 24A through 24C illustrate the process of
inserting the wiper 48 into the slit 81. After the downstream end
of the wiper 48 in the insertion direction passes between the
support plate 72 and the pressing plate 80 of the gripping plate
73, as shown in FIG. 24A, the downstream end contacts the boss 78.
As the wiper 48 is inserted farther, the wiper 48 flexes so that
the downstream end of the wiper 48 slides over the boss 78, as
shown in FIG. 24B. As shown in FIG. 24C, the wiper 48 has been
inserted until the downstream end contacts the restricting plate
75, which prevents further movement downstream in the insertion
direction. At this time, the boss 78 is received in the
through-hole 84 so as to penetrate the wiper 48 in the thickness
direction of the same. When the boss 78 is received in the
through-hole 84, the wiper 48 is interposed between the support
plate 72 and the gripping plate 73 and, therefore, is mounted in
the fixing member 49.
[0263] When the wiper 48 is mounted in the fixing member 49, as
shown in FIG. 21, the boss 78 is inserted through the through-hole
84, preventing the wiper 48 from being removed from the fixing
member 49. Further, the pressing plate 80 restricts the wiper 48
from rising off the support plate 72, thereby fixing the wiper 48
in the fixing member 49.
[0264] However, the wiper 48 can be removed from the fixing member
49 with a sharp needle-like jig 85 shown in phantom in FIG. 24C.
The jig 85 is inserted through the jig insertion part 82 and
between the downstream end of the wiper 48 in the insertion
direction and the depression 83 of the support plate 72 to lift the
downstream end of the wiper 48 off the support plate 72. In this
state, the through-hole 84 can be lifted off the boss 78 so that
the wiper 48 can be subsequently pulled through the slit 81 and
removed from the fixing member 49.
[0265] In the agitator 45 described above, the wiper 48 is fixed to
the fixing member 49 by being inserted into the slit 81 of the
fixing member 49 and, therefore, is fixed to the agitating member
47 of the agitator 45 via the fixing member 49. Further, the fixing
member 49 is integrally formed of the agitating member 47.
Accordingly, the wiper 48 can be fixed to the agitating member 47
through a simple assembly that requires no special parts such as
double-sided tape or a push nut for fixing the wiper 48 to the
agitating member 47. Therefore, this construction reduces the
number of required parts and improves the efficiency of the
assembly operation. Further, since the wiper 48 is fixed to the
fixing member 49 through insertion into the slit 81, the wiper 48
can be removed easily, making the wiper 48 more suitable to
recycling.
[0266] The wiper 48 is inserted and held between the support plate
72 and gripping plate 73, thereby reliably fixing the wiper 48
through a simple construction.
[0267] Further, with respect to the opposing portions of the
support plate 72 and gripping plate 73 between which the wiper 48
is inserted, the first cutout part 76 opposing the gripping plate
73 is formed in the support plate 72, and the second cutout part 79
opposing the support plate 72 is formed in the gripping plate 73.
In other words, only one of the support plate 72 and gripping plate
73 is formed in the opposing portions of the support plate 72 and
gripping plate 73 between which the wiper 48 is inserted, thereby
facilitating removal of the members when molding the support plate
72 and gripping plate 73. Further, toner that enters the slit 81
can easily be cleaned out during recycling.
[0268] When the wiper 48 is inserted into the slit 81 formed in the
fixing member 49, the boss 78 is inserted into the through-hole 84
formed in the wiper 48, thereby more securely fixing the wiper 48
to the fixing member 49 and, by extension, to the agitating member
47.
[0269] The sloped surface 86 of the boss 78 is formed to slope
inward in the direction that the support plate 72 opposes the
gripping plate 73 from the upstream to the downstream side in the
insertion direction.
[0270] As the wiper 48 is inserted downstream into the fixing
member 49, the sloped surface 86 of the boss 78 guides the wiper 48
in a slanted direction. After the downstream end of the wiper 48
slides over the boss 78, the boss 78 becomes inserted into the
through-hole 84 of the wiper 48. This construction enables the
wiper 48 to be mounted smoothly.
[0271] After the boss 78 is inserted into the through-hole 84 of
the wiper 48, the boss 78 prevents removal of the wiper 48 since
the sloped surface 86 of the boss 78 is on the downstream side in
the direction for removing the wiper 48.
[0272] Further, when the wiper 48 is mounted in the fixing member
49, the pressing plate 80 restricts the wiper 48 from floating off
the support plate 72, thereby reliably preventing the through-hole
84 of the wiper 48 from slipping off the boss 78. In this way, the
wiper 48 can be firmly fixed.
[0273] Further, when mounting the wiper 48 in the fixing member 49,
the restricting plate 75 restricts the wiper 48 from being inserted
excessively downstream, thereby reliably fixing the wiper 48 in a
prescribed position.
[0274] For removing the wiper 48 from the fixing member 49, the jig
85 is inserted through the jig insertion part 82, enabling the
developing chamber 42 to be peeled easily from the support plate
72. In this way, recycling can be facilitated.
[0275] Further, since the wiper 48 is formed of a flexible elastic
material, such as urethane rubber, the wiper 48 readily flexes when
mounted in or removed from the fixing member 49, enabling the
through-hole 84 to be fitted over or removed from the boss 78. As a
result, this construction facilitates insertion of the wiper 48 in
the slit 81 and can improve the efficiency of the assembly
operation. The construction also facilitates the removal of the
wiper 48 from the slit 81, making the wiper 48 more suitable for
recycling.
[0276] Since the developer cartridge 30 of the illustrative example
can be constructed with less components and can provide a more
efficient assembly process, as described above, the process
cartridge 20 equipped with the developer cartridge 30 and the laser
printer 1 equipped with the process cartridge 20 can be
manufactured at a reduced cost and can be more suitable for
recycling.
[0277] By employing a structure in the toner-accommodating chamber
41 for inserting the wiper 48 into the slit 81 of the fixing member
49 and fixing the wiper 48 to the fixing member 49, the developer
cartridge 30 described above has the following effects. This
structure prevents impurities from double-sided tape or other
special parts from entering the toner accommodated in the
toner-accommodating chamber 41, which toner is supplied for
development, by eliminating the need for such special parts.
Further, this construction prevents the occurrence of chemical
reactions between toner and the adhesive layers of the double-sided
tape.
[0278] In the illustrative example described above, the boss 78 is
disposed on the support plate 72 and the pressing plate 80 on the
gripping plate 73. However, the boss 78 may instead be disposed on
the gripping plate 73, while the pressing plate 80 is disposed on
the support plate 72.
[0279] In the illustrative example described above, the
through-hole 84 is formed in the wiper 48 for inserting the boss
78. However, the receiving part of the invention for receiving the
boss 78 need not be the through-hole 84, provided that the
receiving part can receive the boss 78 being inserted in the
thickness direction of the wiper 48. For example, a slit 87 that is
substantially U-shaped in a plan view may be cut through the wiper
48 in the thickness direction, as shown in FIG. 25A. With this
construction, the slit 87 can receive the boss 78 being inserted
through the wiper 48 in the width direction, as illustrated in FIG.
25B.
[0280] Further, in the illustrative example described above, the
guide plate 90 of the agitator 45 is formed with a uniform
thickness. However, it is possible instead to form the guide plate
90 thicker in the center region (with respect to the width
direction of the rotational shaft 46) and growing thinner toward
the widthwise ends (the outer ends in the width direction of the
rotational shaft 46). When the agitator 45 rotates to stir the
toner, the surface of the guide plate 90 scraping up the toner is
formed as a sloped surface in which the center portion of the guide
plate 90 is on the upstream side in the rotating direction of the
agitator 45, while both widthwise ends of the guide plate 90 are on
the downstream side.
[0281] The guide plate 90 formed in this way can guide the toner to
flow more smoothly toward the widthwise sides of the
toner-accommodating chamber 41. Hence, the guide plate 90 can
distribute toner in the toner-accommodating chamber 41 more
uniformly in the width direction of the toner-accommodating chamber
41.
[0282] Note, the film 66 and wiper 48 have been omitted from the
agitator 45 shown in FIG. 26.
[0283] Next, the shaft support unit 250 will be described in detail
with reference to FIGS. 27 through 30. As will be described in
detail below, a shaft support unit 250 is disposed on an inner wall
of the developer-accommodating chamber 222. The shaft support unit
250 includes a guiding groove 250a for mounting the agitator shaft
223a, and a holding part 250b for rotatably holding the agitator
shaft 223a (see FIG. 28).
[0284] One end of the agitator shaft 223a is rotatably held in a
through-hole (not shown) formed in an inner wall of the
developer-accommodating chamber 222 opposite the inner wall
provided with the shaft support unit 250. The same end of the
agitator shaft 223a is fitted into a gear (not shown) A motor (not
shown) provided in the laser printer 1 transfers a driving force to
the agitator shaft 223a via the gear.
[0285] As shown in FIG. 27, the other end of the agitator shaft
223a is rotatably held in the shaft support unit 250. As shown in
FIGS. 28 and 30, the shaft support unit 250 includes the holding
part 250b for rotatably holding the agitator shaft 223a, the
guiding groove 250a for guiding the end of the agitator shaft 223a
down toward the holding part 250b, and a restricting part 250c
forming a boundary between the holding part 250b and the guiding
groove 250a for restricting upward movement of the agitator shaft
223a held in the holding part 250b.
[0286] As shown in FIG. 30, the holding part 250b and guiding
groove 250a form recessed parts in the inner wall of the
developer-accommodating chamber 222. The recessed guiding groove
250a is shallower than the recessed holding part 250b in the
recessed direction indicated in FIG. 30.
[0287] The guiding groove 250a has a shaft-confronting surface 501a
that confronts the axial end of the agitator shaft 223a when
mounting the agitator 223 in the developer-accommodating chamber
222. The shaft-confronting surface 501a slopes in a direction
downward and opposite the recessed direction.
[0288] The restricting part 250c has a sloped surface 501c that is
formed continuously with the shaft-confronting surface 501a. The
sloped surface 501c slopes downward, that is, toward the holding
part 250b and away from the shaft-confronting surface 501a in the
direction opposite the recessed direction.
[0289] An introducing surface 254 is also formed on the inner wall
of the developer-accommodating chamber 222. The introducing surface
254 slopes from a deeper position than the guiding groove 250a in
the recessed direction toward the guiding groove 250a and is formed
continuously with an edge 502a at the opening in the top of the
shaft-confronting surface 501a.
[0290] As shown in FIG. 28, the guiding groove 250a has a side
surface 503a for restricting movement of the agitator shaft 223a in
a direction orthogonal to a guiding direction in which the agitator
shaft 223a is guided toward the holding part 250b. A gap 250e is
formed between the side surface 503a of the guiding groove 250a and
the restricting part 250c. The gap 250e is smaller than the
diameter of the agitator shaft 223a.
[0291] The holding part 250b has a polygonal shape in a cross
section taken orthogonal to the axial direction of the agitator
shaft 223a. In this illustrative example, the holding part 250b is
substantially square-shaped in this cross section.
[0292] The widths of the guiding groove 250a and holding part 250b
in a direction orthogonal to the guiding direction for the agitator
shaft 223a are the same.
[0293] As shown in FIG. 27, the transparent windows 251 (only one
is shown in FIG. 27; the other is provided in the inner wall of the
developer-accommodating chamber 222 opposite the wall provided with
the shaft support unit 250) are provided in side walls of the
developer-accommodating chamber 222. A light source (not shown)
disposed outside the developer cartridge 216 transmits a light beam
through the transparent windows 251 for detecting the amount of
residual toner in the developer-accommodating chamber 222. A
flexible wiper 253 is disposed on the agitator 223 for slidingly
contacting the transparent windows 251 as the agitator 223 rotates
in order to clean the transparent windows 251. Beveled parts 260
are formed on edges of the shaft support unit 250 that are
contacted by the flexible wiper 253.
[0294] Next, an operation for mounting the agitator 223 in the
developer-accommodating chamber 222 will be described with
reference to FIG. 30. First, one end of the agitator shaft 223a is
fitted into the through-hole (not shown) formed in the
developer-accommodating chamber 222. Next, the other end of the
agitator 223 is lowered into contact with the edge 502a. The
guiding groove 250a guides this other end of the agitator shaft
223a toward the restricting part 250c as the agitator shaft 223a
flexes. Next, the other end of the agitator shaft 223a is guided
downward along the sloped surface 501c, which forces the other end
of the agitator shaft 223a to move up on the restricting part 50c
in a direction opposite the recessed direction. As the other end of
the agitator shaft 223a is urged downward, the end slides over the
restricting part 250c and becomes fitted into the holding part
250b. At this time, the agitator shaft 223a returns to a straight
extension.
[0295] Since the guiding groove 250a formed on the inner wall of
the developer-accommodating chamber 222 is shallower in the
recessed direction than the holding part 250b, the agitator shaft
223a can be guided toward the restricting part 250c from a shallow
position. This reduces the amount that the agitator shaft 223a must
flex to slide over the restricting part 250c, thereby reducing the
load applied to the agitator shaft 223a compared to the load
applied when the guiding groove 250a and holding part 250b are
formed at the same depth in the recessed direction.
[0296] Since the restricting part 250c has the sloped surface 501c
linked to the shaft-confronting surface 501a for sloping downward
and in the direction opposite the recessed direction, the agitator
shaft 223a flexes gently when the end of the agitator shaft 223a
slides over the restricting part 250c. As a result, this
construction can reduce the load applied to the agitator shaft
223a.
[0297] The inner wall of the developer-accommodating chamber 222
includes the introducing surface 254 that slopes toward the guiding
groove 250a and connects to the open end at the top of the
shaft-confronting surface 501a. Accordingly, the agitator shaft
223a can be smoothly guided to the open end on top of the
shaft-confronting surface 501a.
[0298] A gap 250e having a smaller diameter than the agitator shaft
223a is formed between the side surface 503a and the restricting
part 250c. Accordingly, toner that accumulates in the holding part
250b can escape through the gap 250e. Hence, this structure can
prevent toner from becoming packed between the agitator shaft 223a
and holding part 250b and impeding the rotation of the agitator
223.
[0299] The holding part 250b is substantially square-shaped in a
cross section taken orthogonal to the axial direction of the
agitator shaft 223a. Accordingly, the peripheral surface of the
agitator shaft 223a contacts the holding part 250b at points,
reducing the frictional force generated between the peripheral
surface of the agitator shaft 223a and the holding part 250b.
[0300] By forming the guiding groove 250a and holding part 250b
with the same widths in the direction orthogonal to the guiding
direction of the agitator shaft 223a, it is possible to minimize
the space required for the guiding groove 250a.
[0301] The beveled parts 260 are formed on edges of the shaft
support unit 250 that are contacted by the flexible wiper 253 so as
not to promote degradation in the flexible wiper 253 due to sliding
contact with the shaft support unit 250.
[0302] The shaft-confronting surface 501a of the guiding groove
250a slopes downward in a direction opposite the recessed
direction. With this construction, the agitator shaft 223a flexes
more gently when being mounted in the developer-accommodating
chamber 222 and, hence, a smaller load is applied to the agitator
shaft 223a.
[0303] Although present invention has been described with respect
to specific illustrative examples, it will be appreciated by one
skilled in the art that a variety of changes may be made without
departing from the scope of present invention.
[0304] The process cartridge 20 and developer cartridge 30
described by way of illustrative examples include the plate wall 49
extending vertically downward from the base end 85 toward the
supply roller 37 so that the free end 86 of the plate wall 49 is
positioned close to the peripheral surface of the supply roller 37.
However, the process cartridge 20 or the developer cartridge 30 may
be modified as shown in FIG. 2B while yet retaining many of the
novel features and advantages above-described above. In the
modified process cartridge 20' shown in FIG. 2B, the vertical
length of the plate wall 49' is shortened relative to that of the
plate wall 49 shown in FIGS. 2A, 11, 12 and 15 so that the free end
86 of the plate wall 49' is spaced a greater distance apart from
the peripheral surface of the supply roller 37.
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